New Holland T5.95 T5.105 T5.115 Electro Command Tractor Service Manual (47538922) - PDF Download by www.heydownloads.com

SERVICE MANUAL

SERVICE MANUAL T5.95 / T5.105 / T5.115 Electro Command Tractor

T5.95 T5.105 T5.115 Electro Command Tractor

1/3 Part number 47538922

Part number 47538922 English May 2013

SERVICE MANUAL

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

47538922 29/05/2013 EN

Link Product / Engine Product Market Product T5.105 ElectroCommand International Region T5.105 ElectroCommand Europe T5.105 ElectroCommand North America T5.115 ElectroCommand Europe T5.115 ElectroCommand International Region T5.115 ElectroCommand North America T5.95 ElectroCommand International Region T5.95 ElectroCommand North America T5.95 ElectroCommand Europe

47538922 29/05/2013

Engine F5DFL413B*A006 F5DFL413B*A006 F5DFL413B*A006 F5DFL413A*A002 F5DFL413A*A002 F5DFL413A*A002 F5DFL413C*A003 F5DFL413C*A003 F5DFL413C*A003

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

Transmission.............................................................................. 21 [21.111] Semi-Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.133] Semi-Powershift transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.152] Semi-Powershift transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.118] Transmission/Rear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4

Four-Wheel Drive (4WD) system .................................................. 23 [23.202] Electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 [23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2

Front axle system ....................................................................... 25 [25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

Rear axle system........................................................................ 27 [27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 [27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3 [27.126] Spur gear and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4

Power Take-Off (PTO) ................................................................. 31 [31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 47538922 29/05/2013

[31.116] Three-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3

Brakes and controls .................................................................... 33 [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 [33.220] Trailer brake hydraulic control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.322] Regulated/Low pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.114] Three-point hitch control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

Hitches, drawbars, and implement couplings.................................. 37 [37.110] Rear three-point hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.106] Tie rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

Platform, cab, bodywork, and decals ............................................. 90 47538922 29/05/2013

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

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INTRODUCTION

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Contents INTRODUCTION Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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INTRODUCTION

Capacities Fluid capacities and lubricant specifications approximate

RECOMMENDED NEW HOLLAND AGRICULTURE PRODUCTS Mixture of water and antifreeze NEW HOLLAND AMBRA AGRIFLU at 50 % + 50 %

SPECIFICATION NEW HOLLAND AGRICULTURE

INTERNATIONAL SPECIFICATION

NH 900 A

Cooling system:

16 l (4.2 US gal)

Windscreen wash reservoir

2 l (0.5 US gal)

Water & cleaning liquid

165 l (43.6 US gal)

Decanted, filtered diesel fuel

MAT3521

API CJ-4 ACEA E9

NH 610 A

ISO 7308

NH 410 B

API GL4 ISO 32/46 SAE 10W-30

NH 710 A

NLGI 2

Fuel tank: Engine sump: Minimum.

6.4 l (1.7 US gal)

Maximum

8.1 l (2.1 US gal)

Brake control circuit

0.7 l (0.18 US gal)

Front axle: Final drives (each) Transmission Ring/Pinion Gears final drives and brakes ECM No. hydraulic lift torque of engine at power steering Front wheel hubs

4.5 l (1.2 US gal) 1.0 l (0.3 US gal)

Grease fittings Air-conditioning refrigerant Air-conditioning compressor oil

NEW HOLLAND AMBRA UNITEK CJ-4 ENGINE OIL SAE 10W-40 or NEW HOLLAND AMBRA UNITEK CJ-4 ENGINE OIL SAE 0W-40 NEW HOLLAND AMBRA BRAKE LHM

NEW HOLLAND AMBRA MULTI Gâ&#x201E;¢ HYDRAULIC 63 l (16.6 US gal)

TRANSMISSION OIL

NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE

GREASE

650 g (22.9 oz)

R134 A

0.185 l (0.05 US gal)

SP10

NOTICE: Avoid using fuel with sulfur content higher than 50 mg/kg ( 50 ppm or 0.005% )

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INTRODUCTION

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SERVICE MANUAL Engine

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment 10.3 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

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Engine - 10 Engine and crankcase - 001

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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10.1 [10.001] / 1

Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - Engine and crankcase

Engine - General specification GENERAL SPECIFICATIONS 4 Cylinders Engine, technical type: F5DFL413C*A003 T5.95 F5DFL413B*A006 T5.105 F5DFL413B*A002 T5.115 Engine rpm 2400 - 2500 RPM - high 2300 RPM - nominal 700 - 800 RPM - low Cycle diesel, 4-stroke Fuel injection Direct Number of cylinders in line 4 Bore - All models 99 mm (3.8976 in) − Piston diameter 110 mm (4.3307 in) − Piston stroke Total displacement: 3400 cm³ - All models Compression ratio 17 ± 0.5 : 1 All models Maximum Power Output: 73 kW (99 Hp) − T5.95 79 kW (107 Hp) − T5.105 84 kW (114 Hp) − T5.115 2300 RPM Maximum power speed Peak torque 407 N·m (300.19 lb ft) − T5.95 444 N·m (327.48 lb ft) − T5.105 461 N·m (340.02 lb ft) − T5.115 1500 RPM Peak torque speed Torque increase 34 % − T5.95 35 % − T5.105 32 % − T5.115 Power at the power take−off 62.7 kW (85.1 Hp) − T5.95 68.6 kW (93.3 Hp) − T5.105 73.9 kW (100.4 Hp) − T5.115 Number of main bearings 5 Sump structural, cast iron Lubrication forced, with lobe pump Pump drive from crankshaft Oil filtration mesh screen on oil intake and filter cartridge on delivery line Engine oil pressure switch operating pressures: - contacts closing* with decreasing pressure. 0.2 bar (2.90 psi) - contacts opening* with increasing pressure. 0.9 bar (13.05 psi) * with the contacts closed the engine oil pressure warning light is on Cooling coolant circulation closing with five rows of vertical pipes Capacity 16 l (4.23 US gal) Fan with viscous joint, fixed to the specific pulley ø 520 mm (20.4724 in) intake, in plastic with 10 blades Coolant pump colored scale divided into three sections Coolant thermometer Temperature ranges corresponding to each section: normal temperature − initial dark blue sector high temperature − final red sector dark blue area via thermostat valve − Start of opening 80 °C (176.00 °F) 47538922 29/05/2013

10.1 [10.001] / 3

Engine - Engine and crankcase

GENERAL SPECIFICATIONS

4 Cylinders overhead valves operated by tappets, rods and rocker arms via the camshaft located in the engine block; the camshaft is driven by the crankshaft using straight-tooth gears

Timing

Intake: − start: before P.M.S. − end: after P.M.I. Exhaust: − start: before P.M.I. − end: after P.M.S. Clearance between valves and rocker arms with engine cold. Turbocharging Air cleaning Fuel filtration Priming pump Injection pump Type Nozzles type Injection pressure Filling: Engine sump Fuel tank Anti-pollution system Type:

19 ° 37 ° 61 ° 21 ° The valve clearance is hydraulically controlled. Therefore, manual adjustment is not necessary. Turbocharged with intercooler dual cartridge dry air cleaner, with clogged filter indicator with centrifugal pre-filter and automatic dust ejector by mesh prefilter on the supply pipe, suction line filter with water - fuel separator, low pressure filter and sensor. Manual mounted on the suction line filter BOSCH High pressure Common Rail control unit HPCR - CP4.1 Electro-injectors 300 - 1400 bar (4350.00 - 20300.00 psi) 6.4 - 8.1 l (1.69 - 2.14 US gal) 140 l (36.98 US gal) Exhaust gas recycling system EGR Particulate filter DPF* every 3000 hours

Recommended frequency for renewing filter

NOTE: * - For filter maintenance please refer to: ( Diesel Particulate Filters (DPF) - Dynamic description manual regeneration of the diesel particulate filter (DPF) (55.408))

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Engine - Engine and crankcase

Engine - Install 1.

- Refit the flexible belt on the alternator and take up the slack according to the procedure in Alternator Tension adjust belt (55.301).

- Reposition the compressor and the relevant belt following this procedure: - Reposition the compressor on the support and with the relevant pipe support secure it with the screws - To fit the belt polyv use the tool 380200011. (1). Compressor clutch actuator drive bracket. (2). polyv belt pulley outer edge. (3). Tool recess. It is used to drive the tool; this recess houses the bracket (1). (4). Tail. Used to drive the polyv belt in the pulley seat. (5). Hitching. Thanks to this recess, where the outer edge (2) is housed, the tool remains hitched to the compressor.

WLAPL4S10C101C

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Engine - Engine and crankcase

- Take out the bolts (1) and the related compressor clutch dust cover.

Make sure that the polyv (2) belt is perfectly housed on the fan pulley.

- Move the belt (2) near to the compressor pulley and, keeping the tool 380200011 under the belt, hook it onto the clutch of the compressor at the innermost part so as to slightly force the belt.

6. - With your left hand on the fan and right hand on the tool, move both clockwise so as to take the belt onto the belt of the compressor. - Put the dust cup back onto the compressor clutch and tighten the three screws taking care to spread a film of thread lock on the ends so they do not come unscrewed. 7.

- Where applicable, reposition the viscous joint and the cooling fan.

- Apply the required torque settings ( see engine section)

- Insert the three hooks of the chain in the eyelets on the engine and, using the hoist, lift the assembly off the platform support.

10.

- Position the engine on the front axle, trying to avoid incorrect operations with the hoist so as not to let the engine fan damage the fins of the radiator, then join the two assemblies together with the four retaining bolts and the necessary adjuster spacers for the monobloc/sump support.

11.

- Reposition the movable tool for dismantling tractors 380000569 under the engine and place a wooden block in between the point of contact between the tool and engine.

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WLAPL4S10C142A

WLAPL4S10C143A

Engine - Engine and crankcase

12.

- With the aid of the hoist, place the engine on the tool 380000569 and remove the lifting eye bolts previously fitted on the rear of the engine.

13.

- Remove the fixed stand previously positioned under the support of the groove of the drive of the front axle and the wooden plug.

14.

- Remove the fixed U--bolt fitted beforehand under the ballast support and the two wooden wedges locking the front wheels.

15.

- Remove the old sealing paste from the two surfaces between the engine and clutch casing.

16.

- Apply LOCTITEÂŽ 518 sealing compound on the engine and clutch casing mating surfaces.

17.

- Put a wooden block under the right-hand rear wheel, make sure that the handbrake is fully applied and that all fixed and mobile stands are safely positioned.

18.

- The installation phase described here requires the presence of two or three workers to use the movable tool for dismantling tractors 380000569 to move the engine/front axle assembly close to the gearbox.

19.

- In the phase of installing the engine/front axle assembly to the gearbox, it is necessary to push on the front wheels, taking great care in the end phase of coupling over both the pipes and the cables/electrical connections to prevent crushing between the two bodies. During this phase, it is moreover necessary to turn the crankshaft with the aid of the radiator cooling fan to help the coupling between the sleeve and the drive shaft.

20.

- Secure both assemblies by tightening all the bolts locking the engine to the gearbox.

21.

- Disconnect the hoist chains, remove the U--bolt previously fitted under the clutch casing and recover the movable tool for dismantling tractors 380000569.

22.

- Refit the bracket supporting the cab connectors, cab power and cup filter, connect the pipe that joins the latter to the mechanical priming pump on the sediment filter.

23.

- On the left-hand side, connect the cab power cable connector, take it onto the maxi fuse box and lock it with clamps.

24.

- Return the main engine cable back into position, connect the connectors to the sensors and switches located on the engine, on the control unit and on the maxi fuse box, fasten the wiring with clamps.

25.

- Lay out the FTP interface - engine cable on the machine, reconnect the various connections and secure the wiring with clamps.

26.

- Fit the starter motor back on, then connect the two ground wires on the engine and battery system.

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Engine - Engine and crankcase

27.

- On the right-hand side reconnect the battery positive cable and the wirings to the starter motor, battery cut-off switch and alternator. Fit the guard back onto the starter motor.

28.

- Refit the two delivery and return lines to the cab heater and the pipe inserted on the lower sleeve coming from the expansion tank. Refit the upper and lower sleeves of the radiator engine connection. Secure the straps and clamps tightening the pipes.

29.

- Reconnect the power steering spool valve oil filter together with the support. Reconnect the power steering oil drain pipe and the supply pipe to the spool valve of the gearbox.

30.

- Refit the two oil delivery and return pipes to the cooler and secure them with the relevant clamp.

31.

- Reassemble the power steering pump. Fit back on the transmission oil filter assembly and fix the screws, reconnect the delivery piping to the lift and to the power steering anti-cavitation assembly on the pump, the oil filter inlet from the transmission, and the two suction lines from the filter to the pump.

32.

- Connect the pipes to the power steering cylinder and the supply to the spool valve.

33.

- If it was necessary to remove the DPF support proceed as follows: 1 – Mount the upper support (1) on the right one (2) with the three Allen screws. 2 – Mount the left support (5) securing it to the engine with the three lower screws. 3 – Mount the assembly of the supports (1) and (2) to the engine with the four screws in position (3), respecting the reference marks made when dismantling. 4 – Secure the support (5) to the support (1) with the two upper screws with the two adjustment bushings. 5 – Mount the support (4) to the engine with the two lower screws, fasten the three left screws to the support (5) and with the two upper screws to the support (1)

34.

35.

WLAPL4S10C124A

WLAPL4S10C146A

- Fit the DPF filter assembly back on, returning the entire unit into position and fastening the four fixing screws of the assembly to the cradle. Observation: If after refitting the DPF filter you find a slight misalignment with the axis of the turbine, it is possible to make a correction. On the two screws fixing the filter to the cradle there are two threaded bushings (2) held in position by a grub screw (1). Loosen the grub screw with an Allen wrench, screw the bushing in or out by the amount necessary to correct the misalignment, retighten the grub screw and fix the support. - Refit the upper bracket supporting the casing and secure it with the relevant screws.

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Engine - Engine and crankcase

36.

- Reassemble the air cleaner assembly and the relevant support, fix the screws on the filter bracket and on the inlet pipe on the radiator. Refit the sleeves connected to the turbine, to the engine and to the cooling fan assembly, tighten the relevant clamps. Reconnect the pin of the filter clogging sensor.

37.

- Refit the two pipes to the radiator intercooler and tighten the relevant clamps.

38.

- Fit the exhaust pipe back on and tighten the relevant retaining clamps.

39.

- Refit the transmission oil drain plug. Refill with oil using a pump.

40.

- Refit the propeller shaft together with the central support and the fixing screws, insert the shim and adjust the shaft end float.

41.

- Refit the front axle drive shaft guard, tightening the front, central and rear retaining bolts.

42.

- Reposition the fuel drain plug on the tank.

43.

- Refit the tank lower guard, if applicable, set the fuel tank in position and secure it tightening the relevant retaining clamps. Reconnect the pipes as marked during disassembly.

44.

- Using a hydraulic jack, raise the rear of the tractor, remove the mechanical stand under the left gearbox, return the wheel into position and mount the fixing nuts with a pneumatic gun.

45.

- Reconnect the air-conditioning pipes and the sensor to the condenser, fix them with clamps and brackets.

46.

- Reconnect the air-conditioning pipes on the compressor and lock them with clamps and brackets.

47.

- Recharge the air-conditioning system with refrigerant using the specific control unit 380000315.

48.

- Fit the two engine side panels back on and fix the relevant screws.

49.

- Refit the front wheel mudguards, if applicable, and tighten the relevant fasteners.

50.

- Reposition the pack of ballast weights on the relevant support, fit on the cotter pins and the retaining pin.

51.

- Fit the left steps back on, securing them to the cab.

52.

- Connect the battery negative lead.

53.

- Put the battery cover back on.

54.

- Lower the right-hand cab access steps.

55.

- Refill the radiator with engine coolant.

56.

- Fit the hood back on as described in Hood - Install (90.100)

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Engine - Engine and crankcase

Engine - Remove 1.

Remove the hood (1) as indicated in Hood - Remove (90.100)

Free the bottom steps of the ladder with the retainer (1), raise it with the knob (2), take off the battery cover, detach the battery negative cable.

WLAPL4S10C101A

WLAPL4S10C103A

WLAPL4S10C104A

WLAPL4S10C105A

Remove the split pins, retaining pin and front ballast assembly (1) from the support.

Unscrew the fixing screws (1) and remove the front wheel mudguards (2) (if applicable) Do this on both sides.

Remove the fixing bolts (1) and detach the engine left-hand side panel (2). Carry out the same operation for the rightâ&#x2C6;&#x2019;hand side panel too. Remove the glove compartment.

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Engine - Engine and crankcase

Recover the refrigerant from the system via the connections (1) and (2) using the specific tool 380000315. Detach the pipe (1), clear the section of brackets and clamps, move it onto the condenser ( (1), 6), detach the pipe (2), clear the section and take it to the cab.

WLAPL4S10C106AA

WLAPL4S10C107A

WLAPL4S10C108A

WLAPL4S10C109A

Subsequently go onto the front detach the lower pipe (3) on the condenser (1) free it from any straps or clamps, disconnect the sensor (2) and take it to the cab.

Drain the fuel from the tank by removing the bottom drain plug.

Unscrew the fixing bolts (1) and remove the righthand steps (2).

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Engine - Engine and crankcase

10.

Raise the rear of the tractor with a hydraulic jack, put a mechanical stand under the reduction unit box, with a pneumatic gun remove the left-hand rear wheel retaining nuts, and subsequently take off the wheel.

WLAPL4S10C110A

11.

12.

13.

Detach the tank retaining straps (1), mark and detach the fuel pipes (2) and extract the fuel tank (3). Remove also the bottom tank guard (4)

WLAPL4S10C111A

WLAPL4S10C112AA

WLAPL4S10C113AA

Unscrew the front central and rear retaining bolts on the front axle shaft guard, then remove the guard (1).

Remove the circlip (2) and move the front sleeve (1) in the direction indicated by the arrow until it is released from the groove on the front axle.

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Engine - Engine and crankcase

14.

15.

16.

17.

Remove the circlip (2) retaining the coupling sleeve of the propeller shaft (1) on the back, move the sleeve on the shaft.

WLAPL4S10C114AA

WLAPL4S10C115AA

WLAPL4S10C116A

WLAPL4S10C117A

Take out the screws fixing the central support (1) of the propeller shaft and remove the shaft together with the support, remove also the shaft end float adjuster shim on the back.

Loosen the union of the cab heater radiator coolant return pipe, drain and collect the engine coolant.

Take out the plug (1) and drain the oil from the gearbox--transmission casing.

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Engine - Engine and crankcase

18.

19.

20.

21.

Loosen the device joining the outlet on the filter DPF, free the outlet tube from any brackets fastening it to the cab and remove it.

WLAPL4S10C118A

WLAPL4S10C119A

WLAPL4S10C120A

WLAPL4S10C121A

Loosen the fixing clamps (1) and extract the pipe from the turbine to the radiator intercooler (2) . Carry out the same operation for the pipe from the radiator intercooler to the engine (3).

Loosen the clamp (2) fastening the air intake pipe to the turbine, then free the air cleaner (4) together with the support bracket (3) from the screws fixing it. Disconnect the oil vapor pipe (1) on the left-hand side of the engine at the level of the fuel pump; remove it all.

Free the air cleaner bracket - casing support (1) from the fixing screws and remove it.

ATTENTION: The filter outlet union DPF (1) (2) at its terminal has a decoupler, that responds to temperature variations by changing length.

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Engine - Engine and crankcase

A small misalignment of the axis of the decoupler with respect to the axis of the turbine outlet (3) would produce an adjustment that would no longer be lengthwise, in line with the direction of the tractor, but abnormal transversal adjustment that would impair its durability. 22.

Disconnect all the filter sensors, loosen the clamp (4), remove the entire filter together with the sensors, pressure sensing tubes, lambda probe and heat guards by undoing the four screws (5) fixing it on the bottom cradle.

WLAPL4S10C122A

WLAPL4S10C123A

WLAPL4S10C124A

WLAPL4S10C125A

ATTENTION: Only if you have to work on the parts underneath the DPF support, it is advisable to remove the support. The top part (1) and the right-hand part (2) should be removed as a block, when possible, by removing the fixing screws (3) to the right of the engine (these screws work on a vertical slot that allows the support (2) to take on various positions in height). Before disassembly, take some references on the position of the unit on the engine, so that during reassembly it is possible to restore it to the exact position in which it was first found.

23.

24.

To remove the rear guard, unscrew the two upper screws fastening the support (4) support (1), to remove the left support, (5) unscrew the two upper screws for the centering bushings and that secure the left bracket to the support (1). As regards removing the support (1) and (2) there are no special instructions to follow.

Detach the steering system pipes (1) and (2) the pipe delivering oil to the spool valve (3). Remove the fixings of the bracket (4) from the engine

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Engine - Engine and crankcase

25.

Detach the power steering spool valve outlet pipe on the gearbox spool valve (2), on the same filter detach the gearbox spool valve supply pipe (1). Subsequently remove the filter together with the support (3).

26.

Disconnect the intake pipes from the pump (1) on the pump itself, the oil filter intake pipe from the transmission (2), on the junction under the transmission, at the height of the cab support. Disconnect the delivery line to the lift (3) again at the height of the pipe (2). Detach the delivery pipes (5) to the lift and to the power steering anti-cavitation tank (6) on the pump.

27.

Detach the unit together with the filter (4), tank (6), support and the parts of piping disconnected previously.

28.

Detach the high pressure - power steering pump unit.

29.

Detach the pipes of the cooler (1), differential lock (3) and, if applicable, front braking assembly (4).

30.

Free the pipes previously detached from the supports, brackets and clamps secured to the engine, do the same thing also for the pipes directed to the steering system cylinder (2).

31.

WLAPL4S10C126A

WLAPL4S10C127A

WLAPL4S10C128A

WLAPL4S10C134A

On the right-hand side, detach the cab heating pipes, (1), the pipe inserted on the engine sleeve. (3) coming from the expansion tank, then, loosen the clamps and, on the engine, detach the lower (4) and upper rubber sleeves joining radiator - engine.

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Engine - Engine and crankcase

32.

On the right-hand side, remove the guard (1) on the starter motor (2), disconnect the starting cable, the battery cut-off switch, the cable joining it to the alternator, also disconnect the alternator and the battery positive terminal, free all the wirings detached from the various clamps.

33.

Detach the clamp bolt (3) then remove the ground cables of the engine and battery system, remove the other clamp bolts of the motor and remove it.

34.

On the cable (1) of the FTP cable - engine interface detach all the connections (2), leave only those on the maxi fuse box and on the glow plug control unit, then, after cutting the clamps, collect the cable on the front near the control unit (5).

35.

On the main engine cable (3) disconnect the connectors, starting from the one on the control unit (4), from the maxi fuse box and from the various switches and sensors located on the engine and, after freeing it from the clamps, move it onto the back at the height of the right-hand steps.

36.

On the left-hand side disconnect the connector of the power cable of the cab (1), free it from the clamps and move it onto the maxi fuse box.

37.

Detach the bracket (2) supporting the cab connectors, cab power and cup filter (3), disconnect the pipe that joins the latter to the mechanical priming pump on the sediment filter.

38.

WLAPL4S10C135A

WLAPL4S10C137A

WLAPL4S10C139A

WLAPL4S10C129A

Hook the rear part of the engine onto a hoist using chains or ropes for the hoisting (apply two eye bolts, one to the right and one to the left, on the upper part of the flange containing the flywheel). Position a fixed stand (2) under the clutch housing (1) near the engine attachment flanging and apply the handbrake.

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Engine - Engine and crankcase

39.

40.

41.

42.

Position the movable tractor stand 380000569 (2) (1) with the bracket and adapter plate under the engine and place a wooden block in between the points of contact between the stand and engine. Wedge the axle to prevent swinging.

WLAPL4S10C140A

WLAPL4S10C130A

WLAPL4S10C131AA

WLAPL4S10C132AA

Remove the fixing screws (1) between the engine and the transmission.

Separate the engine (1) from the transmission with the tool 380000569 (2).

Insert the fixed stand (1) under the ballast support and secure the front wheels with wooden blocks (2).

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Engine - Engine and crankcase

43.

44.

45.

46.

Position a fixed stand (3) under the support of the groove (1) of the front axle drive placing a wooden plug between parts (3) and (1).

WLAPL4S10C133A

WLAPL4S10C136A

WLAPL4S10C141A

WLAPL4S10C138A

Set a stand under the back of the engine so as to be able to release the hoist with the coupling device in full safety. Add a rope or chain also on the front of the engine and take up the slack with the lifting device, keeping the engine balanced.

Remove the bolts (1) fastening the front axle support (2) to the engine. Remove the adjuster spacers for the support - monobloc (4) / sump (3).

Check that there are no brackets between the engine and the cooling assembly, detach the engine (2) from the front axle, (3) trying to avoid incorrect movements with the hoist in order not to damage the radiator fins (1) with the engine fan. Rest the engine (2) on a support.

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Engine - Engine and crankcase

47.

Remove the viscous coupling (1), where applicable, together with the fan (2).

48.

Loosen the compressor fixing screws (4), remove the belt (5), then remove the compressor.

49.

Completely unscrew the belt tensioner (2), remove the flexible belt (3), then remove the alternator (1).

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WLAPL4S10C144A

WLAPL4S10C145A

Index Engine - 10 Engine and crankcase - 001 Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - 10 Fuel tanks - 216

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Engine - 10 Fuel tanks - 216

SERVICE Fuel tank Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Fuel tanks

Fuel tank - 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

Lift the steps (1), remove the battery guard and detach the negative battery cable (2).

MOIL12TR00738AA

MOIL12TR00737AA

MOIL12TR00739AA

Using a hydraulic jack, remove the left wheel (1) and place a suitable stand under the axle.

Remove the lower left mudguard extension (1).

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Engine - Fuel tanks

Remove the steps (1) together with the guard (2).

MOIL12TR00740AA

MOIL12TR00741AA

Remove the tool box (1).

Remove any diesel still left in the tank with a pump.

NOTE: There are two plastic refuelling unions on the rear of the tank, one at the bottom and one at the top, sealed with a rubber cap and a clip; the tank can also be emptied from the bottom union. 7.

Remove the bottom tank guard (1).

MOIL12TR00742AA

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Engine - Fuel tanks

10.

Remove the breather pipe (1) as well as the suction and return pipe (2).

MOIL12TR00743AA

MOIL12TR00744AA

Very carefully remove the screws holding the front (2) and rear brackets in place on the relative racks. Place a mechanical jack under the tank (1), touching on the bottom. With the help of another person holding the tank to keep it balanced, now lift if by approximately 2 cm (0.8 in), move it to the right of the machine so that the straps unhook from the racks. Then lower it all by around 3 cm (1.2 in) รท 5 cm (2.0 in) so that the tank fits under the step support.

The rest the tank on a pallet and then remove the straps.

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Engine - Fuel tanks

Fuel tank - Install For reassembly operations proceed as follows: 1.

With the help of another person and a mechanical jack, hook the tank with the brackets back on to the front (1) and rear racks.

The screw on the screws holding the straps onto the relative racks.

Fit the breather pipes (1), suction pipe and return pipe (2) back on.

MOIL12TR00745AA

MOIL12TR00743AA

MOIL12TR00742AA

Re-assemble the bottom tank guard (1).

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Engine - Fuel tanks

Re-assemble the tool box (1).

MOIL12TR00741AA

MOIL12TR00740AA

MOIL12TR00739AA

MOIL12TR00737AA

Re-assemble the step (1) and the guard (2).

Re-assemble the left lower mudguard extension (1).

Replace the left wheel (1).

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Engine - Fuel tanks

Reconnect the negative battery cable (2) and reposition the step (1).

MOIL12TR00738AA

10.

Fill up the tank with fuel.

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Index Engine - 10 Fuel tanks - 216 Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment - 501

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Engine - 10 Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment - 501

TECHNICAL DATA Diesel Particulate Filters (DPF) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification Installation measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Exhaust Gas Recirculation (EGR) valve Dynamic description manual regeneration of the diesel particulate filter (DPF) . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Diesel Particulate Filters (DPF) Remove for periodic replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install for periodic replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove DPF with support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install on the DPF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install DPF with support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Diesel Particulate Filters (DPF) - Torque

MOIL12APL92

TORQUE SETTINGS No. 1 2 3 4 5 6

Part to tighten Gas temperature sensor on DPF intake DPF filter first section temperature sensor Pressure pipe fitting on turbine side Pressure pipe fitting on muffler side Lambda sensor Air temperature sensor

Thread size M 14x1.5

Nm 40.5 to 49.5

Torque settings kg lbf. ft 4.14 to 5.12 30.2 to 36.9

M 14x1.5

40.5 to 49.5

4.14 to 5.12

30.2 to 36.9

M M M M

40.5 to 49.5 27 to 33 45 to 55 15 to 25

4.14 to 5.12 2.80 to 3.42 4.66 to 5.70 1.55 to 2.59

30.2 to 36.9 20.1 to 24.6 33.6 to 41 9 to 18.6

14x1.5 12x1.5 18x1.5 12x1.5

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Diesel Particulate Filters (DPF) - General specification Installation measurements

MOIL12APL104

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Measurements to respect for installing the filter — Legend of components — Legend of sensor fixing holes: 1.

308.6 mm (12.1496 in)± 1.5 mm (0.0591 in) Distance between the two bands of the cradle, the one with the set fixing holes (10) and the one with the adjustable fixing holes (11) .

46 mm (1.8110 in)± 1 mm (0.0394 in) Distance between the centre of the turbine or the centre of the union of the decoupler/turbine and the adjustable filter fixing bushings (12) .

134 mm (5.2756 in)± 1 mm (0.0394 in) Distance between the centre of the turbine or the centre of the union / turbine and the band supporting surface (4) with set fixing holes on the filter support.

Band supporting surface with set fixing holes.

Initial part of the DPF filter, connected with the sleeve. (15) to the turbine.

Middle part of the DPF filter, inside which there is the ceramic part to clean.

End part of the DPF filter, connected with the sleeve. (14) to the exhaust pipe.

Clamp retaining the middle part (6) \ end part (7) .

Clamp retaining the middle part (6) \ initial part (5) .

10. Band with the set fixing holes. 11. Band with the adjustable fixing holes. 12. Threaded bushings, screwing them in or out enables changing the adjustment distance (3) . 13. Grub screw fixing the bushing (12) . 14. Filter outlet union, it is inserted on the exhaust pipe. 15. Union joining the filter to the turbine. 16. Clamp fixing the union (15) to the filter. 17. Tutor, protects the decoupler during the handling from the supplier, it is dismantled after assembly (it is advised to keep one to hand and to reassemble it before starting to disassemble the filter so that the decoupler undergoes no deformation). 18. Gas pressure detection after the middle part of the filter, the pipe that goes on the differential pressure sensor is connected here. 19. Gas pressure detection before the middle part of the filter, the pipe that goes on the differential pressure sensor is connected here. 20. Exhaust gas temperature sensor from the turbine. 21. Exhaust gas temperature sensor to the intake of the middle part of the filter. 22. Lambda sensor.

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Exhaust Gas Recirculation (EGR) valve - Dynamic description manual regeneration of the diesel particulate filter (DPF) A diesel particulate filter (DPF) is a device designed to remove polluting diesel engine particulate from exhaust gas; when clogged, it needs to be regenerated. The diesel particulate filter can be regenerated automatically or by forcing. The regeneration process is signaled to the operator on the central monitor of the dashboard and with an acoustic signal. The indication is necessary for the purposes of safety to warn the operator about the high exhaust temperature reached during the process. The automatic regeneration shall not affect engine performance. During the procedure, the operator can continue working normally. Under certain operating conditions automatic regeneration might not be completed (engine continuously stopping and starting, lengthy periods at idle speed) and it must then be repeated. The start of automatic regeneration, if set, is highlighted with the following warning light blinking on the dashboard and the same symbol appears every 5 minutes on the central monitor with the word “ON” combined with a single beep. On concluding the operation the symbol appears with the word “OFF” . When the level of soot exceeds a certain level, the electronic control unit asks you to proceed with manual filter regeneration. NOTICE: If the filter is not regenerated when required, whether manually or by forcing, the functionality of the filter is impaired. Continuing to ignore this request, besides greatly reducing engine horsepower, damages the filter to such an extent that it is necessary for the dealer to replace the filter with a new one. When the following warnings appear on the dashboard it is necessary to proceed as follows:

DPF to be regenerated Start of automatic regeneration or, with the control, start of forced regeneration Image legend: (A) - Warning light on the dashboard (B) - Flasher (C) - On (D) - Off (E) - Central display

WLAPL4S55C111A

DPF to be regenerated Low severity Automatic regeneration inhibited, only start of forced regeneration with control

DCAPLT5NE058S3A

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

DPF to be regenerated High severity Automatic regeneration inhibited, only start of forced regeneration with control

DCAPLT5NE059S3A

DCAPLT5NE060S3A

DPF damaged Technical support required Automatic and forced regeneration inhibited

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Manual regeneration of the diesel particulate filter DPF

DCAPLT5NE072S3F

To be able to activate the procedure of manual regeneration when required, it is necessary to stop work for the entire duration of the procedure ( 15 — 20 min) and get into the following conditions: • engine running, machine stationary and hand brake on • hand throttle at minimum position • foot throttle released • PTO not engaged • hydraulic system not active NOTE: If the conditions described above are changed, throughout the entire process of regeneration, the operation is stopped. To activate forced regeneration, proceed as follows: • Press the switch (2) on the symbol (B) for more than three seconds to enter the programming menu The central monitor will show “SETUP MENU”. Release the symbol (B). • Press the switch (3) on the symbol (D) a number of consecutive times until the monitor shows the symbol of the filter (S1). • Press the switch (2) on the symbol (B). • If manual filter regeneration is required, the monitor will automatically display “START” with the symbol of the filter. • Press the switch (2) on the symbol (B) to move on to the message “WAIT” . Filter regeneration now commences. In this phase, if everything proceeds normally, the operator must give no commands and the electronic control unit will automatically display the various phases of the procedure. • At the end of regeneration the monitor will show “OFF” with the filter symbol . After two seconds the control unit automatically returns to the initial situation. Press the switch (2) on the symbol (A) a number of times until you exit the programming menu. NOTE: If during manual regeneration the operator modifies the conditions described above, or other conditions connected with the engine are not satisfactory, regeneration is stopped. The stop is signaled to the operator by the 47538922 29/05/2013

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

monitor displaying the filter symbol together with “FAIL” and a single acoustic signal. After 2 seconds, the control unit goes back into the situation at the start of regeneration “START”. From this situation, after restoring the necessary conditions to carry out the operation it is necessary to press the switch (2) on the symbol (B) to restart the regeneration procedure.

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Automatic diesel particulate filter regeneration inhibition DPF

DCAPLT5NE071S3F

If you want to inhibit or enable automatic regeneration of the diesel particulate filter, proceed as described below: • Press the switch (2) on the symbol (B) for more than three seconds to enter the programming menu The central monitor will show “SETUP MENU”. Release the symbol (B). • Press the switch (3) on the symbol (D) a number of consecutive times until the monitor shows the symbol of the filter S1 . • Press the switch (2) on the symbol (B) and press the switch (3) on the symbol (D) to display the screen S2 then press button (B) • YES = automatic regeneration of the filter INHIBITED • NO = automatic regeneration of the filter ENABLED • It is possible to change the setting status by moving with the direction keys of the switch (3) on the symbols (C) and (D)to pass from “yes” to “no” and vice versa, then confirm by pressing the switch (2) on the symbol (B). If automatic regeneration is disabled the following warning light on the dashboard remains on steady

and every 5 minutes the central monitor shows the following symbol combined with a single beep. If the setting in the system matches the needs of the work to perform, press the switch (2) on the symbol (A) a number of times to exit the programming menu. NOTICE: It is always advisable to have the automatic regeneration function ENABLED.

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Diesel Particulate Filters (DPF) - Remove for periodic replacement 1.

Using the lever (1)pull the steps upwards, remove the cover (2) , then disconnect the negative battery lead.

MOIL12APL91

MOIL12APL106

MOIL12APL111

MOIL12APL113

Raise the bonnet, disconnect the headlights connector from the engine cable. Remove the bonnet (1) see, Hood - Remove (90.100) .

NOTE: Remove the hinge from the support leaving this under the bonnet. 3.

Remove the side panels (2) on both sides.

Loosen the clamp of the connection pipe (1) between the air cleaner (3) and turbine, unscrew the retaining screws of the air intake pipe (2) then slide it towards the front so that it comes out of the filter inlet. Then, after disconnecting the clogged filter sensor connection, remove the filter from the bonnet support.

Disconnect the connectors on the pressure differential sensor (1) , on the two temperature sensors and on the lambda sensor, unscrew the system heat shield (2) and position everything on the left-hand side of the engine.

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Remove the bonnet support (1) .

Unscrew the pressure differential unit (1) with its pipes, brackets, clamps and sensor.

Unscrew the temperature sensor (2).

10.

MOIL12APL115

MOIL12APL125

MOIL12APL114

MOIL12APL112

Unscrew the filter's upper heat shield (1), the lower one stays in position.

Mark the filter as shown in the figure.

NOTE: The right-hand marking must include the first part of the filter, the middle part (1) including the clamp joining them (2) . The left-hand one will include the middle part, the left-hand one and the clamp (3) .

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

11.

Loosen the clamp (1) joining the muffler to the DPF outlet pipe. The clamp (2) , that keeps the filter outlet pipe parallel to the filter's first section.

MOIL12APL107

12.

13.

14.

Remove the left-hand clamp (1) fastening the filter to the machine.

MOIL12APL109

MOIL12APL105

MOIL12APL110

Loosen the left-hand clamp (1) fastening the middle and left parts of the filter.

Remove the left part of the filter (1) , with the clamp (2) removing the copper gasket.

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

15.

Subsequently, after loosening the right-hand clamp (1) , remove the middle part of the filter (2) .

MOIL12APL108

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Diesel Particulate Filters (DPF) - Install for periodic replacement NOTE: For the torque settings please refer to , Diesel Particulate Filters (DPF) - Torque (10.501) . 1.

Reassemble the middle part of the DPF filter with the relevant clamp; tighten the clamp, paying attention to the orientation of the parts.

Reassemble the left part of the DPF filter with the relevant clamp; tighten it, paying attention to the orientation of the parts.

NOTE: If the clamp and the gasket are rusty and in a poor condition, change them. 3.

Reassemble the left-hand clamp fastening the filter on the cradle.

Position the collar fastening the filter pipe to the muffler and tighten it, tighten also the top of the collar that fixes the pipe to the cradle.

Fit the filter upper heat shield back on.

Fit the temperature sensor back on.

NOTE: To reassemble the pressure differential unit proceed as described in chapter Diesel Particulate Filters (DPF) - Install on the DPF filter (10.501) . 7.

Fit the hood support back on.

Reassemble the system heat shield and reconnect the pressure, lambda and pressure differential sensors, position the wiring harness and, if necessary, secure it with ties.

Fit the air cleaner onto the hose connecting it to the turbine, then secure it to the hood support with the relevant screws.

10.

Tighten the clamp on the hose, run the intake duct towards the filter then tighten it with the relevant screws; reconnect the connector to the clogged filter sensor.

11.

Reassemble the hood see, Hood - Install (90.100) .

12.

Reconnect the battery cable, replace the cover and lower the steps.

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Diesel Particulate Filters (DPF) - Remove DPF with support 1.

Using the lever (1) pull up the steps, take off the cover (2) , then disconnect the battery negative cable.

Raise the hood, disconnect the headlights connector from the engine cable, then, after having slung it to the hoist with a belt, remove the hood (1) see, Hood - Remove (90.100) .

Remove the side panels (2) on both sides.

With the air conditioning circuit gas recovery power pack, recover the gas (1) .

Disconnect the air conditioning pipes (1) , on the control panel side.

Loosen the clamp (1) , retaining the air cleaner / turbine connection pipe, unscrew the screws on the air intake pipe (2) , then run it towards the front so as to make it come out of the air cleaner.

Disconnect the connector on the clogged filter sensor, unscrew the filter (3) from the hood support and extract it.

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MOIL12APL91

MOIL12APL106

MOIL12APL93

MOIL12APL94

Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

10.

11.

MOIL12APL113

MOIL12APL115

MOIL12APL97

MOIL12APL98

Remove the complete hood support (1) .

In the gap on the left of the brakes reservoir, behind the filter, take out the screws (1) that join the cross support (2) of the filter and the rear support (3) .

Remove the brakes reservoir heat shield (1).

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

12.

Loosen the clamp (1) fastening the exhaust pipe to the DPF filter.

MOIL12APL99

13.

14.

15.

Using a belt, sling the muffler, at two points at least, take up the slack with a hoist. Take out the screws (2) fastening the exhaust pipe (1) to the support (3) . Then extract all of the pipe from the right-hand side of the tractor and put it down on a pallet on the ground.

MOIL12APL100

MOIL12APL101

MOIL12APL102

Put two eyebolts (1) on the screws retaining the upper heat shield of the filter. Using a chain, hook on the filter and take up the slack in the chains.

On the left-hand side, under the filter remove the two screws (1) on the adjustment bushings (3) of the filter left support (2).

NOTE: After taking out the screws, unscrew the bushings so as to create a gap between the filter assembly and the left support.

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

16.

On the right-hand side, loosen the clamp (1) , for fixing the filter decoupler to the turbine, move it towards the front. Take out the three hex socket screws (2) fastening the right support (3) to the transversal one.

NOTE: These screws have been fitted by the supplier and a few drops of Loctite have been used to prevent them, over time, from coming loose.

MOIL12APL103

17.

Using the hoist, raise the filter, taking great care that there are no wiring harnesses and tie-rods connected or obstructing the passage, then rest the filter with the cross support on a workbench.

NOTE: With the machine in these conditions it is possible to work on the engine, for example on the valve cover, and, if the right-hand support is not removed, it is possible to reassemble the filter without making any special adjustments.

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Diesel Particulate Filters (DPF) - Install on the DPF filter NOTE: For the torque settings please refer to chapter Diesel Particulate Filters (DPF) - Torque (10.501) . NOTICE: When reassembling this unit on the filter (1), the sequence for assembling the components and tightening the parts of the components must follow a strict procedure.

MOIL12APL114

MOIL12APL118

MOIL12APL119

MOIL12APL120

Fit the support bracket (1) for the exhaust pressure pipe on the turbine side with the relevant screws.

Fit the exhaust pressure pipe (1) on the turbine side with the relevant retaining clamps.

Tighten in sequence the pipe clamp (1) , the fitting (2) .

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Fit the exhaust pressure pipe (1) on the muffler side with the relevant retaining clamps.

MOIL12APL126

MOIL12APL122

MOIL12APL123

MOIL12APL116

Fit the differential sensor retaining bracket (1) and tighten the relevant screws.

Tighten in sequence the pressure pipe clamp (1) on the muffler side, the pressure pipe clamp (2) on the turbine side and the pressure pipe fitting (3) on the muffler side.

Fit the pressure differential sensor (1) on the relevant bracket and tighten the screw.

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Connect the pressure pipe on the turbine side (1) and muffler side (2) to the sensor and tighten the collars.

MOIL12APL124

Reconnect the battery cable, replace the cover and lower the steps.

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Diesel Particulate Filters (DPF) - Install DPF with support NOTE: For the torque settings, please refer to chapter Diesel Particulate Filters (DPF) - Torque (10.501), for the measurements to observe when assembling the filter please refer to chapter Diesel Particulate Filters (DPF) - General specification Installation measurements (10.501), for the various adjustments of the filter support please refer to chapter Engine - General specification (10.001). For reassembly, proceed as follows: 1.

Hook the filter onto the hoist and lower it onto the engine.

Screw the filter with the support beneath the right support with the three hex socket screws, and tighten them fully.

NOTE: Apply a few drops of Loctite 270 on the screws. 3.

On the left support, screw the two bushings in until they come into contact with the cross support, then screw in the two connecting screws.

Detach the chains from the filter and remove the eyebolts.

Again using the hoist, take the exhaust pipe and reposition it on the filter outlet, secure it with the screws to the support, then position the connecting clamp for the filter outlet pipes - exhaust pipe intake and tighten it. Slacken the hoist, disconnect the belt and put it aside.

Reassemble the brakes reservoir heat shield.

Reassemble the rear support fixing screws to the cross support.

Reassemble the bonnet support, tighten the screws.

Reassemble the connectors on the sensors, then reposition the heat shield and tighten the screws.

10.

Reassemble the air cleaner, position the pipe joining it to the turbine and tighten the clamp. Position the suction pipe and tighten the fixing screws, reconnect the clogged filter connector.

11.

Reconnect the air conditioning pipes, make a vacuum with the power pack and introduce gas into the circuit.

12.

Reassemble the side panels and the bonnet.

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Index Engine - 10 Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment - 501 Diesel Particulate Filters (DPF) - General specification Installation measurements . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Diesel Particulate Filters (DPF) - Install DPF with support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Diesel Particulate Filters (DPF) - Install for periodic replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Diesel Particulate Filters (DPF) - Install on the DPF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Diesel Particulate Filters (DPF) - Remove DPF with support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Diesel Particulate Filters (DPF) - Remove for periodic replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Diesel Particulate Filters (DPF) - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exhaust Gas Recirculation (EGR) valve - Dynamic description manual regeneration of the diesel particulate filter (DPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - 10 Fan and drive - 414

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Engine - 10 Fan and drive - 414

SERVICE Belt Tension adjust belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Fan and drive

Belt - Tension adjust belt If the belt tension is insufficient, check the belt tensioner as indicated below. 1.

Loosen the screw in the slot of the belt tensioner (3) and that of the alternator pivot (1) , the belt tensioner tie-rod / alternator fastening screw (2) then loosen the lock nut of the screw at the end of the belt tensioner (4) .

WLAPL4S55C301A

WLAPL4S55C301B

The drive belt is tensioned as follows: 2.

Tighten the screw of the belt tensioner tie-rod to reset the lower slot of the tie-rod, in practice it must be pulled fully, as it is an elastic belt.

Tighten the lock nut of the screw ( (5) , 1 ), tighten the other three screws of the belt-tensioner tie-rod ( (1) , (2) and (3) , 1). Components of figure 2: (1) . Alternator pulley. (2) . Coolant pump. (3) . Alternator. (4) . Fan hub. (5) . Belt-tensioner tie-rod.

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Index Engine - 10 Fan and drive - 414 Belt - Tension adjust belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

NEW HOLLAND AGRICULTURE policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND AGRICULTURE Dealer.

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SERVICE MANUAL Transmission

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Transmission - 21

[21.111] Semi-Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[21.133] Semi-Powershift transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[21.152] Semi-Powershift transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[21.118] Transmission/Rear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

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Transmission - 21 Semi-Powershift transmission - 111

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Transmission - 21 Semi-Powershift transmission - 111

TECHNICAL DATA Semi-Powershift transmission Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Semi-Powershift transmission Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Hydraulic schema (Diagrams 1st gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Transmission housing cover Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SERVICE Semi-Powershift transmission Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Transmission housing cover Remove Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Assemble Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Disassemble - Transmission top cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Visual inspection Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

DIAGNOSTIC Semi-Powershift transmission Testing - Tractor does not drive in any gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Testing - The tractor remains in the range gear but with the following fault: . . . . . . . . . . . . . . . . . . . . . . . . 67 Testing - The Powershift gears are not progressive or the tractor loses traction during gear changes. 68

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Testing - The tractor works in all gears but with the following fault: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Testing The tractor works in all gears but with the following fault: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Testing The tractor drives in all gears and in all ranges but has the following fault: . . . . . . . . . . . . . . . . . 70 Testing - Tractor drives in all gears and ranges but has the following fault: . . . . . . . . . . . . . . . . . . . . . . . . 70

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Torque

MOIL12TR00691AJ

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Transmission - Semi-Powershift transmission

No.

Part to tighten

Thread size

Flexible coupling retaining screw* Shuttle control valve retaining screw on gearbox Fork retaining dowel Fork retaining dowel tightening nut Hex socket screw Hex socket screw Shaft support retaining bolt Hi - LO range control lever fixing screw Gear box control valve retaining screw Solenoid valve retaining rod fixing screw Core Plug Fork spring retaining plug Potentiometer casing retaining screw Potentiometer retaining screw Gearbox/engine retaining screw Gearbox/engine retaining screw Gearbox/engine retaining nut Gearbox primary shaft front bearing adjusting shim retaining screw Gearbox shaft front bearing support retaining screw Pipe retainer hex socket screw on clutch C1 and C2 manifold Gearbox front cover fixing screw Clutch C1 and C2 manifold fixing screw on cover

M8X22

Nm 30 to 34

M 10X20

40.5 to 49.5

4.1 to 5.0

29.8 to 36.5

M10 M10

24 to 30 27 to 33

2.4 to 3.0 2.7 to 3.3

17.7 to 22.1 19.9 to 24.3

6.9 13 43 21

0.7 1.3 4.3 2.1

0.8 1.5 5.4 2.6

5.0 to 5.8 9.5 to 11.0 31.7 to 39.0 15.4 to 19.1

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

19 20 21 22

M6x12 M6x20 M10x65 M8x25

to to to to

7.9 15 53 26

Tightening torques Kgm ft lb 3.0 to 3.4 22.1 to 25.0

to to to to

M10

43 to 53

4.3 to 5.4

31.7 to 39.0

M6x12

6.9 to 7.9

0.7 to 0.8

5.0 to 5.8

7/16 20UN 9/16 18UN M5X20

20 to 30 16 to 24 1.7 to 2.3

2.0 to 3.0 1.6 to 2.4 0.17 to 0.23

14.7 to 22.1 11.8 to 17.7 1.25 to 1.69

M5X50 M12 M12 M12 M8X30

1.7 to 2.3 125 to 135 125 to 135 105 to 115 21 to 26

0.17 to 0.23 12.7 to 13.7 12.7 to 13.7 10.7 to 11.7 2.1 to 2.6

1.25 to 1.69 92.1 to 99.5 92.1 to 99.5 77.4 to 84.8 15.4 to 19.1

M10x35

43 to 53

4.3 to 5.4

31.7 to 39.0

M10x20

43 to 53

4.3 to 5.4

31.7 to 39.0

M10X28 M10x35

43 to 53 43 to 53

4.3 to 5.4 4.3 to 5.4

31.7 to 39.0 31.7 to 39.0

* Apply a drop of LOCTITE 270 on the thread

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Sectional view Gear A B C D E F G H J K S M N O P R

Name C1 clutch driven gear C2 clutch driven gear Front lower shaft gear Front lower shaft gear Reverse gear Forward gear and/or coupling Main gear for low gear range Lower idler shaft gear Lower idler shaft gear Lower idler shaft gear C4 clutch driven gear C3 clutch driven gear (high gear range) C3 clutch driven gear (low gear range) Driven Gear Driven gear for high gear range Driven gear for low gear range

40 Km/h 37 29 41 48 33 37

Number of teeth 35 Km/h (Japan)

53 37 41 25 41 45

37 41

â&#x20AC;&#x201D;

38 34

43 39

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Transmission - Semi-Powershift transmission

BSE3841A

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Transmission - Semi-Powershift transmission

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Dynamic description This transmission offers 16 or 17 forward, and 16 reverse ratios. An optional reduction gear set (creeper gears) offers a further 16 ratios, forward and reverse. The transmission is switched by the gear lever, two powershift buttons (2), to shift up, (3) to shift down and a range change button (1). On the left side panel there are additional transmission controls, powershift buttons (4), to shift up, (5) to shift down) and a third button (3) to change range; for use when the operator is driving looking at the implement on the rear of the tractor. The shuttle lever, to the left of the steering wheel, is used to select forward or reverse gear.

MOIL12TR00692AA

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Transmission - Semi-Powershift transmission

Display Of Gears The display in the centre of the dashboard shows a range of information, including the selected gear. There are eight oval indicators, the one lit shows the gear in power shift, selected in the range (3) selected (LO for gears 1 to 8, HI from 9 to 16). The forward gear (11) must be shown above the tractor directions. The reverse gear (4) must be shown under the tractor directions. The number of the current gear must be greater than the selected shuttle gear. The current forward gear must be shown by the corresponding lit indicator, when the current gear is forward. The current reverse gear must be shown by the corresponding lit indicator, when the current gear is reverse. The up arrow (7) must be on if the current tractor direction is Forward and the down arrow (5) must be off. The down arrow must be on if the current tractor direction is reverse and the up arrow must be off. If the current direction is Forward and the selected direction is Backward, the Up arrow must be on and the down arrow must be flashing, and vice versa. When the tractor is in Neutral ( "N”), the tractor shape (6) must disappear and in its place there must be a “N”. When the tractor is in Neutral ( "N”), the upper number must be as small as the lower number. When the tractor is in Neutral ( "N”), a dotted line is shown in the range box.

MOIL12TR00693AA

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Transmission - Semi-Powershift transmission

Auto take- off (ATO) The Auto Take Off feature ( ATO) permits the operator to engage drive without using the clutch pedal by simply moving the shuttle lever from neutral to the forward or reverse position. The ATO function is automatically enabled under normal starting conditions. i.e. operator in the driving seat, clutch pedal depressed and the shuttle lever in neutral. After selecting the chosen gear range with the gear lever, simply move the shuttle lever to the forward or reverse position without depressing the clutch pedal. The Auto Take Off function ( ATO) will provide a controlled start from rest.

MOIL12TR00694AA

NOTE: The Auto Take Off function ( ATO) will be disabled if the vehicle is at rest with the shuttle lever in the neutral position and the operator leaves the seat. Should Auto Take Off be disabled for any reason, the operator should carry out the following procedure to re- enable this function. Sit in the seat, release the parking brake and cycle the clutch pedal. The vehicle will then move off in the direction selected on the shuttle lever. Once enabled, the Auto Take Off function ( ATO) will continue to function as long as the operator remains in the seat.

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Transmission - Semi-Powershift transmission

Transmission drive Gear

Description

A B C D E F

C1 clutch driven gear C2 clutch driven gear Front lower shaft gear Front lower shaft gear Reverse gear Forward gear and/or coupling Main gear for low gear range Lower idler shaft gear Lower idler shaft gear Lower idler shaft gear C4 clutch driven gear C3 clutch driven gear (high gear range) C3 clutch driven gear (low gear range) Driven Gear Driven gear for high gear range Driven gear for slow speed gears

G H J K S M N O P R

MOIL12TR00695FA

Number of teeth 40 km/h 30 km/h (Japan) 37 29 41 48 33 37 53 37 41 25 41 45

37 41

â&#x20AC;&#x201D;

38 34

43 39

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Transmission - Semi-Powershift transmission

Power flows - neutral position (idle)

MOIL12TR00695FA

Engine power is transmitted from the flywheel mounted flexible coupling damper to the input/PTO driveshaft and clutch housing C1/C2, which is splined to the shaft. Hydraulic clutches engaged • No clutch engaged.

MOIL12TR00697AA

Synchronizer Position • In the neutral position (N), the clutches (C1) and (C2) are disengaged, the drive is not transmitted to the clutch casing C1/C2. • All synchronisers are shown in the neutral position.

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Transmission - Semi-Powershift transmission

Power flows - first gear

MOIL12TR00698FA

Drive shaft - (C2) - forward/reverse gear synchroniser - gears F-J-K-G - synchroniser 1-4/5-8 - (C4) - gears L-O-P-M-N-R - Hi/Lo range synchroniser - output shaft. Hydraulic clutches engaged • Clutches (C2) and (C4) are engaged.

MOIL12TR00699AA

Synchronizer Position • Having engaged the forward gears, 1-4 gears and low range. • If the gradual coupling pedal is depressed, the (C4) clutch is disengaged.

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Transmission - Semi-Powershift transmission

Power flows - second gear

MOIL12TR00696FA

Drive shaft - (C2) - forward/reverse gear synchroniser - gears F-J-K-G - synchroniser 1-4/5-8 - (C3) - gears N-R - Hi/Lo range synchroniser - output shaft. Hydraulic clutches engaged • Clutches (C2) and (C3) are engaged.

MOIL12TR00700AA

Synchronizer Position • Having engaged the forward gears, 1-4 gears and low range. • If the gradual coupling pedal is depressed, the (C3) clutch is disengaged. • The automatic passage from 1st to 2nd gear engages the clutch (C3) and disengages the clutch (C4), changing the power flow on the rear of the transmission.

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Transmission - Semi-Powershift transmission

Power flows - third gear

MOIL12TR00701FA

Drive shaft - (C1) - gears A-C-D-B - forward/reverse gear synchroniser - gears F-J-K-G - synchroniser 1-4/5-8 - (C4) - gears L-O-P-M-N-R - Hi/Lo range synchroniser - output shaft. Hydraulic clutches engaged • Clutches (C1) and (C4) are engaged.

MOIL12TR00702AA

Synchronizer Position • Having engaged the forward gears, 1-4 gears and low range. • The automatic passage from 2nd to 3rd gear involves the following clutches: from (C2) to (C1) from (C3) to (C4)

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Transmission - Semi-Powershift transmission

Power flows - fourth gear

MOIL12TR00703FA

Drive shaft (C1) - gears A-C-D-B - forward/reverse gear synchroniser - gears F-J-K-G synchroniser 1-4/5-8 (C3) - gears N-R - Hi/Lo range synchroniser - output shaft. Hydraulic clutches engaged • Clutches (C1) and (C3) are engaged.

MOIL12TR00704AA

Synchronizer Position • Having engaged the forward gears, 1-4 gears and low range. • The automatic passage from 3rd to 4th gear engages the clutch (C3) and disengages the clutch (C4).

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Transmission - Semi-Powershift transmission

Power flows- fifth gear

MOIL12TR00705FA

Drive shaft (C2) forward/reverse gear synchroniser - synchroniser 1-4/5-8 - C4 - gears L-O-P-M-N-R - Hi/Lo range synchroniser - output shaft. Hydraulic clutches engaged • Clutches (C2) and (C4) are engaged.

MOIL12TR00699AA

Synchronizer Position • Having engaged the forward gears, 5-8 gears and low range. • Synchro shift passage from range 1-4 to range 5-8 with the range change button, the transmission controller disengages the clutches (C1) and (C3) and engages the clutches (C2) and (C4).

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Transmission - Semi-Powershift transmission

Power flows - eighth gear

MOIL12TR00706FA

Drive shaft (C1) gears A-C-D-B forward/reverse gear synchroniser - synchroniser 1-4/5-8 (C3) N-R gears Hi/Lo range synchroniser - output shaft. Hydraulic clutches engaged â&#x20AC;˘ Clutches (C1) and (C3) are engaged.

MOIL12TR00704AA

Synchronizer Position â&#x20AC;˘ Having engaged the forward gears, 5-8 gears and low range.

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Transmission - Semi-Powershift transmission

Power flows - 16th gear

MOIL12TR00707FA

Drive shaft (C1) gears A-C-D-B forward/reverse gear synchroniser - synchroniser 1-4/5-8 (C3) gears M-P Hi/Lo range synchroniser - output shaft. Hydraulic clutches engaged â&#x20AC;˘ Clutches (C1) and (C3) are engaged.

MOIL12TR00704AA

Synchronizer Position â&#x20AC;˘ In the high gear ranges, the Hi/Lo range synchroniser engages on the output shaft gear (P) providing a higher transmission ratio from the clutches (C3) and (C4).

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Transmission - Semi-Powershift transmission

Power flows - second reverse gear

MOIL12TR00708FA

Shifting to reverse, the forward/reverse gear synchroniser engages the range (E). The clutch (C2) transmits the driver through the E-R1-H-K-G gears, inverting the direction in the (C3) clutch. Hydraulic clutches engaged â&#x20AC;˘ Clutches (C2) and (C3) are engaged.

MOIL12TR00700AA

Synchronizer Position â&#x20AC;˘ The forward/reverse gear synchroniser provides reverse traction for all forward gears (1-16).

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Static description

MOIL12TR00709FA

The transmission drive can be split into the following three sections: Clutches (C1) and (C2) - located at the front of the transmission to work in conjunction with (C3) and (C4) to give 4 basic ratios.

MOIL12TR00710AA

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Transmission - Semi-Powershift transmission

Forward/reverse gear synchroniser - located in the central part of the transmission to select the direction forward/ reverse and is electro-hydraulically controlled by the PWM valves. 1-4/5-8 synchroniser - located right behind the forward/reverse gear synchroniser, to select the ranges.

MOIL12TR00710AA

(C3) and (C4) clutches located in the rear section of the transmission each supplying a single gear ratio in conjunction with (C1) and (C2) to give 4 basic ratios. The high and low gear range synchroniser, located at the back of the transmission, when in conjunction with the clutches (C1), (C2), (C3), (C4) and the 1-4 / 5-8 synchroniser, offers a total of 16 gear ratios forwards and 16 in reverse.

MOIL12TR00711AA

The transmission is powered through a flywheel vibration damper and has no conventional clutch.

MOIL12TR00712AA

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Transmission - Semi-Powershift transmission

The pressurised oil needed to engage the clutch is supplied by the discharge of the steering circuit (power-assisted steering). It maintains a pressure of between 17 bar (246.5 psi) ÷ 18 bar (261.0 psi) ( 17.3 kgm (125.1 ftlbs.) ÷ 18.3 kgm (132.4 ftlbs.) ) from the low pressure regulating valve (3), located in the head of the services control valve (1) near the fitting (2) where the oil is supplied from the steering circuit. The excess oil comes out of the cover from the output (4) and is used for lubrication.

MOIL12TR00713AA

Through the pipe (1) the oil passes through a pressure filter and enters the transmission valve (2), to engage the clutches, subsequently, through the pipe (3) it leaves the valve and enters the accumulator (6). The accumulator immediately provides more oil to fill any gaps left when gear changes take place using a number of clutches. Through the output (2) it reaches the services control valve.

MOIL12TR00714AA

A an oil cooler by-pass valve (1), mounted on the services control valve head (3), immediately after the pipe fitting (2), ensures that any excess oil pressure built up during cold start or due to a block in the cooler, excludes the cooler until the oil heats up (reducing the pressure to below 0.5 bar (7.2 psi) ( 5.9 kgm (42.7 ftlbs.) ± 0.5 kgm (3.6 ftlbs.)). The output (4), if the oil is hot, and connected to the cooler, from the oil pipe (2) returns to the head from the cooler.

MOIL12TR00715AA

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Transmission - Semi-Powershift transmission

After the cooler the oil reaches the transmission valve (2), and from here exist via the pipe (3) to reach the services control valve head.

MOIL12TR00716AA

Again in the services control valve head (2) there is a first valve (3) which regulates the lubrication pressure (3) calibrated to 7.8 bar (113.1 psi) Âą 0.5 bar (7.2 psi) ( 7.9 kgm (57.1 ftlbs.) Âą 5.5 kgm (39.8 ftlbs.)).

MOIL12TR00717AA

Inside the transmission valve another control valve with a second valve is fixed, which regulates the lubrication with a valve (1) calibrated to 7 bar (101.5 psi) ( 7.1 kgm (51.4 ftlbs.)), regulated in this way the oil lubricates all the transmission parts, clutches, shafts and synchronisers.

MOIL12TR00718AA

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Transmission - Semi-Powershift transmission

INLET SENSORS The clutch engagement is controlled by signals from the various sensors and switches:Transmission oil temperature sensor This sensor (1) measures the transmission oil temperature and compensates it if the oil is too hot or too cold.

MOIL12TR00719AA

Potentiometer and clutch pedal decoupling switch The clutch pedal potentiometer (1) ensures the controlled coupling by the operator of the clutches with progressive coupling proportioning (C3, C4). The clutch decoupling switch (2) cuts off the power to the modulating valves on the range change clutches (C3/C4), consequently decoupling the traction.

MOIL12TR00720AA

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Transmission - Semi-Powershift transmission

Shuttle lever . Via the switches, the inverter lever (1) provides information to the controller concerning the transmission direction, forward or reverse, or the neutral position . It disengages power to all transmission PWM valves when in neutral.

MOIL12TR00721AA

Forward/reverse gear and 1-4/5-8 range potentiometers . Provide information to the controller on the position of the forward and reverse synchroniser, potentiometer (1), and the 1-4/5-8 gear synchroniser, potentiometer (2).

MOIL12TR00722AA

Gear lever . Gear lever The gear lever (1) is used both the select the gears and the range. When selecting the high or low gear range (moving the lever forwards or back) you must always press down the clutch pedal too

MOIL12TR00723AA

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Transmission - Semi-Powershift transmission

Synchroniser state switches . Provide information to the controller on the position of the High/Low synchroniser . Low gear range status (1) and high gear range status switch (2).

MOIL12TR00724AA

Gears . The automatic gear up (2), automatic gear down (6) and 1/4-5/8 range gear (1) switches allow the operator to select 8 basic ratios, sending a signal to the controller without using the clutch pedal. For particularly heavy duty operations (ploughing, when driving watching the implement coupler) there are three buttons (respectively (4), (5) and (3)) used to make gear up/gear down operations smoother.

MOIL12TR00692AA

Park brake switch This switch is used to apply the parking brake during calibration, an event in which if it is not applied an error code is issued . The tractor will drive if the parking brake is applied but an audible alarm will be heard.

MOIL12TR00725AA

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Transmission - Semi-Powershift transmission

Seat Switch. Seat switch must be operated, i.e. the operator must be seated, before the controller allows the engagement of forward or reverse drive.

MOIL12TR00726AA

NOTE: A faulty switch can be excluded by the clutch pedal.

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Transmission - Semi-Powershift transmission

OUTPUT DEVICES PWM valves for clutches C1, C2, C3 and C4 . Controls the oil supply to the clutches allowing the engagement/disengagement of the clutches via a signal supplied from the transmission controller.

MOIL12TR00727AA

Forward, Reverse, 1-4 and 5-8 PWM Valves . Controls the oil supply to the transmission top cover allowing the engagement/disengagement of the synchronizer to select forward, reverse, 1-4 and 5-8 via a signal from the transmission controller.

MOIL12TR00728AA

Analogueâ&#x2C6;&#x2019;digital instrument cluster (ADIC) . Provides information to the operator if a critical fault occurs with the transmission operation.

MOIL12TR00729AA

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Transmission - Semi-Powershift transmission

CONTROL DEVICE Controller Via the PWM valves, the controller (1) precision manages the four multi-disk oil bath clutches in the transmission. The unit also controls changes in direction without having to use the clutch. The transmission is equipped with diagnostic functions that interpret a certain number of faults, which can be viewed or saved, according to their criticality.

MOIL12TR00730AA

The control valve assembly is mounted on the side of the transmission. It is supplied with low pressure oil through the point (2) at a pressure of 17 bar (246.5 psi) รท 18 bar (261.0 psi) ( 17.3 kgm (125.1 ftlbs.) รท 18.3 kgm (132.4 ftlbs.)) via an accumulator.

MOIL12TR00731AA

Behind the control valve assembly there is a combined lubrication valve assembly. It incorporates the regulating valve (1), combined valve (2) with spool and spring (4) and the selector valve (3).

MOIL12TR00732AA

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Hydraulic schema (Diagrams 1st gear) Key to transmission hydraulic diagrams Symbols Oil delivery at regulated pressure of 17 bar (246.5 psi) รท 18 bar (261.0 psi) from the services control valve head

Symbols legend Regulated pressure delivery

Lubrication delivery from the return side of the cooler.

Regulated pressure or zero pressure line to the tank

Combined lubrication valve

Lubricating oil

Lubrication selector valve

Line coupler points

Lubrication delivery to the differential

Line restriction

Lubrication delivery to synchronisers and gear shafts

Pilot control valve under pressure

Accumulator 10 bar (145.0 psi)/ 0.7 l (0.2 US gal)

PWM valve

Calibrated lubrication circuit relief valve 7 bar (101.5 psi) C1 Clutch 1

Solenoid valve

Clutch 2

Positive voltage applied

Clutch 3

Tank

Clutch 4

Spring control

PWM = modulating valve (with pulse width modulation)

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Transmission - Semi-Powershift transmission

1ST GEAR SELECTED, GRADUAL COUPLING PEDAL PUSHED FULLY DOWN • The oil from the power steering circuit passes through a pressure filter and reaches the services control valve cover; it is regulated to a pressure of 17 bar (246.5 psi) ÷ 18 bar (261.0 psi) and sent (1) to the side cover of the transmission through the accumulator (7). • The excess oil in the low pressure circuit, regulated to 17 bar (246.5 psi) ÷ 18 bar (261.0 psi), through a by-pass valve protecting the cooler, which allows the cold oil to reach a first lubrication valve calibrated to 7.3 bar (105.8 psi) ÷ 8.3 bar (120.4 psi). If the oil is hot it is sent to the cooler, and returns to the transmission valve via the output (2). A second lubricating valve (8) limits the oil pressure to 7 bar (101.5 psi). • The oil at a regulated pressure of 17 bar (246.5 psi) ÷ 18 bar (261.0 psi) is sent to: Clutch C1 PWM valve Clutch C2 PWM valve Clutch C3 PWM valve Clutch C4 PWM valve Combined lubrication valve (3). Since the PWM and solenoid valves are not energised, there is no flow of regulated pressure oil. • The lubrication oil is sent to the combined lubrication valve, which is moved to the left by the relative spring. • From the combined lubrication valve the oil is sent to: C1/C2 clutches C3/C4 clutches Output gear shafts and synchronisers (6) PTO clutch and output differential (5)

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Transmission - Semi-Powershift transmission

MOIL12TR00733HA

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Transmission - Semi-Powershift transmission

1ST GEAR SELECTED, GRADUAL COUPLING PEDAL PARTIALLY RAISED • When the gradual coupling pedal is partially raised, the C2 clutch PWM valve opens fully, sending the maximum oil pressure 17 bar (246.5 psi) ÷ 18 bar (261.0 psi) to clutch C2. • The lubrication logic valve on clutches C1/C2 (8) is moved to the left by the pressure of clutch C2, increasing the lubrication of clutch C2 and reducing the lubrication on clutch C1. • As the gradual coupling pedal is released further, the clutch C4 PWM valve is progressively energised. As the application pressure on clutch C4 increases, from zero to 2 bar (29 psi), the lubrication oil moves: A) In a regulated manner restricting the clutches C1 and C2, lubricating clutch C2, where the piston, packing the disks, has opened the pipe. B) More abundantly it moves to clutches C3 and C4, lubricating clutch C4 more where the piston starts to move and frees the lubrication pipe • Pressure regulated oil is combined with existing C3/C4 lubrication oil to increase lubrication oil flow during clutch application. Lubrication to transmission and PTO is reduced during clutch application.

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Transmission - Semi-Powershift transmission

MOIL12TR00734HA

1ST GEAR SELECTED, GRADUAL COUPLING PEDAL FULLY RAISED â&#x20AC;¢ When the gradual coupling pedal is fully released, the clutch C4 PWM valve is fully energised. 47538922 29/05/2013

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Transmission - Semi-Powershift transmission

â&#x20AC;˘ When the clutch C4 application pressure exceeds 15 bar (217.5 psi), the combined lubrication valve is moved fully to the right. Pressure regulated oil is no longer combined with the lubrication oil. Transmission and PTO lubrication is restored. â&#x20AC;˘ The clutch application pressure is taken to a maximum of 18 bar (261.0 psi)

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Transmission - Semi-Powershift transmission

MOIL12TR00735HA

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Transmission - Semi-Powershift transmission

Transmission housing cover - Exploded view

MOIL12TR00736GA

Exploded diagram of the top cover 1 1-4/5-8 rod retaining assembly 3 Transmission Top Cover 5 Shaft spacer 7 Shaft support 9 Potentiometer spacer 11 Forward/reverse detent assembly 13 Forward/reverse engagement fork 15 End Cap 17 1-4/5-8 control fork 19 1-4/5-8 clutch piston and oil seal 21 Snap ring (seeger) 23 Forward gear PWM valve 25 1-4 PWM valve

2 1-4, 5-8 potentiometer 4 Potentiometer control shaft 6 ”O-Ring” seal 8 ”O-Ring” seal 10 Forward/reverse potentiometer 12 Forward/reverse control fork rod 14 Forward/reverse piston and oil seal 16 Snap ring (seeger) 18 1-4/5-8 control fork rod 20 End Cap 22 Reverse gear PWM valve 24 PWM valve retaining plate 26 5-8 PWM valve 47538922 29/05/2013

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Remove Prior operation: Removing the cab, refer to Cab - Remove (90.150) .Removing the auxiliary fuel tank - refer to Fuel tank - Remove (10.216) .Removing the engine and front transmission support - refer to Engine - Disconnect (10.001). 1.

Disconnect the wiring harness (1) as required to enable the separation of the transmission from the rear axle.

MOIL12TR00746AA

MOIL12TR00747AA

MOIL12TR00748AA

Remove the right steps (1) and the guard to the left.

Detach the ventral control valve from the pipes, supply, exhaust and pilot control (if the valve is closed centre type). Remove the control valve and the support (2). Remove the battery holder (3) and the battery. Harness the cab support (4) together with the battery tray and remove it from the gear box.

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Transmission - Semi-Powershift transmission

Remove the accumulator (1) and support (2) and all the pipes in the hydraulic circuit connected to it and connected to the transmission valve (3).

MOIL12TR00749AA

MOIL12TR00750AA

MOIL12TR00751AA

From the left side, remove the cab/tank support (1), suction pipe (2) and the bracket, the brackets (3) with the pipes connected to it.

Assembly the lifting hooks 380001116, (1) to the transmission. Using a suitable chain, attach the transmission to a hoist. Position the splitting kit (3) 380000569 beneath the tractor. Use the splitting kit supports (2) to support the rear transmission on the stand.

Remove the transmission to rear axle retaining bolts. Disconnect the transmission from the rear axle.

Next operation: Semi-Powershift transmission - Disassemble (21.111)

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Disassemble Prior operation: Remove the transmission (see Semi-Powershift transmission - Remove (21.111)).

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

Using the locally fabricated stand attachment bracket, install the transmission on a suitable stand.

MOIL12TR00753AA

MOIL12TR00754AA

MOIL12TR00755AA

Remover the top cover from the transmission (see Transmission housing cover - Remove (21.111)). Remove the transmission valve (see Transmission control valve - Remove (21.133)). Remove the spring holding the high/low gear range control rod in place (1), the poppet ball actuator (2) and the poppet ball (3).

Remove the low (1) and high (2) gear range switches from the gearbox.

NOTE: The range switch threads are of a different diameter and cannot be mixed up.

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Transmission - Semi-Powershift transmission

Clutch - Remove (21.152)series tractor.

Gears - Remove (21.152)series tractor.

Clutch Speed clutch - Remove (21.152).

Clutch - Disassemble (21.152)series tractor.

Clutch Speed clutch - Visual inspection (21.152).

Clutch Master clutch - Assemble (21.152).

10.

Gears - Disassemble (21.152).

11.

Gears - Assemble (21.152).

12.

Clutch Speed clutch - Disassemble (21.152).

13.

Clutch Speed clutch - Visual inspection (21.152).

14.

Clutch Master clutch - Assemble (21.152).

Next operation: Semi-Powershift transmission - Assemble (21.111).

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Assemble Prior operation: Semi-Powershift transmission - Disassemble (21.111), Semi-Powershift transmission - Service instruction (21.111). 1.

Install the shaft (3), retaining pin (2) and woodruff key (4). Install the selector actuator (5) and tighten the fixing screw (1).

MOIL12TR00756AA

MOIL12TR00757AA

MOIL12TR00758AA

Install the C3/C4 clutch and oil supply manifold assembly into the transmission housing.

Install the C3 clutch output shaft.

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Transmission - Semi-Powershift transmission

Install the output shaft, high/low gear range synchroniser and coupling fork as a single assembly.

MOIL12TR00759AA

MOIL12TR00760AA

MOIL12TR00761AA

MOIL12TR00762AA

Install the high/low gear range selector fork rod (3) .Install the fork rod fixing screw (2) and lock nut (1), then tighten to the specified torque value.

Install the high/low gear range switches. Tighten to the specified torque value.

NOTE: Consider that the switches have different diameter threads and cannot be mixed up.

Install the rear cover assembly, then fix it with the relative screws.

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Transmission - Semi-Powershift transmission

10.

Rotate the transmission until the rear part is in a vertical position .Using a suitable lever (5), list the output shaft assembly (1) in order to be able to install the snap ring .Install the roller bearing thrust washer (4), the 'D' washer (3) and the elastic ring (2).

MOIL12TR00765AA

MOIL12TR00766AA

Rotate the transmission to a vertical position. Install the main range synchroniser and the main low gear range assembly (1).

Using suitable snap ring pliers, widen the snap ring (1) and install the low gear range synchroniser in the transmission housing.

MOIL12TR00767AA

11.

Rotate the transmission to a horizontal position.

NOTE: Take care when lifting heavy components. NOTE: To facilitate re-assembly, it may be necessary to apply vaseline to the synchroniser components and the roller bearings.

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Transmission - Semi-Powershift transmission

12.

13.

14.

Install the inner cover assembly (1) in the transmission housing, without fixing it.

MOIL12TR00768AA

MOIL12TR00769AA

MOIL12TR00770AA

MOIL12TR00771AA

Align the inner cover assembly (1) with the synchroniser, the lower shaft and the reverse return gear.

Rotate the transmission to a vertical position. Install the inner cover plate fixing screws (1) and tighten to the specified torque value.

NOTE: Make sure that the inner cover assembly is aligned with the synchroniser, the lower shaft and the reverse return gear.

15.

Gears - Clearance (21.152).

16.

Install the PTO input shaft (1).

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Transmission - Semi-Powershift transmission

17.

18.

19.

20.

Install the C1/C2 clutch (3), the output gear (2) and the lower front support shaft (1).

MOIL12TR00772AA

MOIL12TR00773AA

MOIL12TR00774AA

MOIL12TR00775AA

Install the roller bearing on the output gear of the C1 clutch (2), the front roller bearing (4) and the flap (1).

Clean and carefully grease the mating surfaces and apply a strip of sealant of approx. 2 mm (0.1 in) in diameter, following the pattern shown in the figure.

Install the O-rings (2) and the front cover plate (1).

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Transmission - Semi-Powershift transmission

21.

Loosely install the C1/C2 clutch support manifold .Install the C1/C2 clutch support manifold fixing screws.

NOTE: Do not tighten the screws at this point.

22.

23.

MOIL12TR00776AA

MOIL12TR00777AA

MOIL12TR00778AA

Install the retaining bracket (1) on the oil transfer pipe and the lubrication oil supply pipe (2).

Tighten the fixing screws on the front cover (1), the clutch support manifold (2) and the rod fixing screws (3) .

Next operation: Install the transmission valve (see Transmission control valve - Overview (21.133)) .Install the upper transmission cover (see Transmission housing cover - Exploded view (21.111)).

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Service instruction Prior operation: Semi-Powershift transmission - Disassemble (21.111)series tractor. 1.

It is recommended that the transmission is disassembled in the sequence indicated. Removal of components of the transmission with the transmission oriented as shown in the colour diagram will facilitate operations.

MOIL12TR00752AA

Yellow- Front Section Brown- Rear Section

Green/Red- Middle Section

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Transmission - Semi-Powershift transmission

The transmission must be removed from the tractor before commencing the overhaul. Should any single component be identified as requiring removal refer to the relevant area within the overhaul procedure and consider if replacement of this single item can be achieved without complete disassembly.

NOTICE: Cleaning is an important part of the overhaul. Ensure during the rebuilding stage that all contaminant is eliminated, the transmission uses hydraulically actuated components and that cleanliness and the removal of any contaminant is paramount to a successful overhaul. Pay particular attention to the control valve when this is removed during this overhaul stage. 3.

During disassembly and reassembly operations, the transmission must be placed either horizontally or vertically using a special stand. See Semi-Powershift transmission - Special tools (21.111) for further information .Alternatively an engine stand of sufficient strength together with a suitable bracket may be used.

MOIL12TR00753AA

Next operation: Mechanical transmission - Install (21.114).

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Inspect Prior operation: Semi-Powershift transmission - Disassemble (21.111). 1.

Before commencing a detailed inspection of the transmission components, consider the history of the transmission. If the disassembly and overhaul operations are required due to a specific fault which requires relatively little manpower, a careful review of the components will allow the identification of any bearings, gaskets or other parts that may be recovered. If, however, the transmission has operated considerable service hours, then replacement of all bearings and gaskets would be recommended.

Wash all components, including the transmission housing, in a suitable solvent and dry using a lint free cloth or compressed air. Unless otherwise stated, during reassembly Semi-Powershift transmission - Assemble (21.111) of the components described in this chapter, lubricate them with clean gear oil NEW HOLLAND AMBRA MULTI G 134â&#x201E;˘ HYDRAULIC TRANSMISSION OIL NEW HOLLAND AMBRA MULTI Gâ&#x201E;˘ HYDRAULIC TRANSMISSION OIL.

Next operation: Semi-Powershift transmission - Assemble (21.111).

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Pressure test 1.

Pressure test ports are provided on the transmission control valve cover, illustrated in Figure 3, to enable the transmission clutches and lubrication pressures to be tested to determine the correct function of a number of system components. Components such as solenoids, clutch pedal operation and micro-processor can be seen to be operating correctly by the results of pressure testing.

NOTE: Before proceeding with the pressure tests, make sure that all the required preparations have been done on the tractor in order to work in total safety. 2.

Start and operate the tractor to warm the transmission oil to a minimum operating temperature of 50 Â°C (122.0 Â°F). Apply the parking brake. Remove the four-wheel drive shaft. Raise the right hand rear wheel and place a suitable support under the axle casing. Remove the right hand rear wheel. Disconnect the grey electrical connector from the high gear range switch and install the switch by-pass connector 380001147 (1) on the tractor wiring harness terminal. By installing the bypass connector, the processor receives a signal indicating that the high gear range has been selected, even if the GEAR LEVEL is in NEUTRAL throughout the tests. MOIL12TR00781AA

MOIL12TR00782AA

Disconnect the differential lock solenoid connector (1).

C1/C2 and C3/C4 clutch coupling and decoupling pressure test Remove the caps from the pressure test ports, see figure 3, and install the adaptors: - C1 / C2 clutch quick release fitting 380000492. - 7/16 JIC male x 7/16 UNF male adaptor and quick release fitting 380001146 for C3/C4 clutches. â&#x20AC;˘ Pressure test port thread 7/16 -20 UNF

NOTE: Table 8 shows the progressive coupling test on the C3 clutch, the pressures measured with the progressive coupling test on the C4 clutch must be the same as those measured for the C3 clutch.

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Transmission - Semi-Powershift transmission

Connect four pressure gauges with scale 0 - 40 bar ( 0 - 600 lbf/in²) 380000552, using the quick release coupling 380000543 (2). The test must be carried out with two pressure gauges, using the following procedure: - Connect to C1 and C2 pressure test ports and carry out the tests from the gears nine to twelve. - Connect to C3 and C4 test ports and carry out tests from gears nine to twelve. - Connect to C2 and C3 test ports with gear 10 selected and carry out C3 transmission declutching test. - Connect to C2 and C4 test ports with gear 9 selected and carry out C4 transmission declutching test. Place the shuttle lever to Forward and leave the range gear lever in Neutral. Take the engine RPM to 1500 rev/min, to measure the system working pressure, or to 2200 rev/min, for maximum system pressure. Take the reading from the pressure gauges and compare them with the values shown in table 4 for the gear change phases, table 5 for the transmission declutching tests, and table 6 for the shuttle forward/reverse/neutral position tests.

Lubrication pressure test Prepare the tractor as described above. Remove the cap from the pressure test port, see 3, and install the quick release fitting 380000492. • Pressure test port thread 7/16 -20 UNF Connect a pressure gauge with scale from 0 - 10 bar ( 0 - 145 lbf/in²) 380000551, using the quick release coupling 380000543 and the flexible pipe 380000544. 3 bar ( 44 lbf/in²) - Neutral 2 bar ( 29 lbf/in²) - Forward/Reverse

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Transmission - Semi-Powershift transmission

MOIL12TR00783GA

Identification of pressure test ports and solenoid valves 1 C4 clutch pressure test port 3 C3/C4 clutch lubrication pressure testing pressure test port 5 Lubrication pressure test port 7 C2 clutch pressure test port 9 C1 clutch pressure test port 11 Oil temperature sender 13 Clutch C2 PWM valve 15 Clutch C4 PWM valve

2 C3 clutch pressure test port 4 Lubricating inlet connector 6 Regulated pressure inlet 8 C1/C2 clutch lubrication pressure testing pressure test port 10 Bearing/transmission synchroniser lubricating pressure 12 Clutch C1 PWM valve 14 Clutch C3 PWM valve

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Transmission - Semi-Powershift transmission

MOIL12TR00784GA

Pressure tests - Clutch PWM valve operation A. B.

C. D.

E. F.

C2 C2 C3 C4 C2 C1 C2 C4 C1 C1 C3 C4 C1

and C4

and C3 and C3 and C4

and C3

Full pressure Full pressure 0 - 2 bar : 2 - 18 bar 18 - 17 bar : 17 - 0 bar Full pressure 0 - 2 bar : 2 - 18 bar 18 - 17 bar : 17 - 0 bar 0 - 18 bar Full pressure Full pressure 0 - 2 bar : 2 - 18 bar 18 - 17 bar : 17 - 0 bar Full pressure

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Transmission - Semi-Powershift transmission

MOIL12TR00785FA

Transmission declutching tests for C3 clutch - Gear 10 selected A. B. C. D.

When the clutch pedal is pressed at first, the pressure in C3 must fall by approximately 2 bar compared to full engagement pressure. When the clutch pedal is fully depressed C2 and C3 pressures should be zero. Releasing the clutch pedal from the fully depressed position should restore C2 to full pressure and C3 to declutching pressure. Pressure in C3 should progressively increase as the clutch pedal is released indicating the PWM solenoid valve and clutch potentiometer are functioning correctly.

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Transmission - Semi-Powershift transmission

MOIL12TR00786FA

Shuttle forward/neutral/reverse position test - gear 9 selected A. B. C.

Full pressure C2 and C4 18 - 0 bar C2 and C4 C2 Immediate return to full pressure C4 Engagement controlled up to full pressure NOTE: Disengage the parking brake to carry out the shuttle test and make sure that the RANGE GEAR LEVER remains in NEUTRAL

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Transmission - Semi-Powershift transmission

MOIL12TR00787FA

Clutch lubrication pressure test - gear 9 selected A.

C2 and C4 C1/C2 lubrication C3/C4 lubrication C2 C4 C1/C2 lubrication C1/C2 lubrication C2 C4 C1/C2 lubrication C1/C2 lubrication

Zero pressure About 0.5 bar About 0.5 bar Full pressure 0 - 2 bar About 0.75 bar About 2 bar Full pressure Full pressure About 0.75 bar Reduced to 1 bar

Forward/reverse and 1-4 / 5-8 range synchroniser pressure test 7.

Slide the operator seat fully backward. Remove the rubber mat from the cab. Remove the cab floor panel from the cab.

MOIL12TR00788AA

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Transmission - Semi-Powershift transmission

Remove the caps from the pressure test ports and install the quick release fitting 380000492 in the forward (F), reverse (R) and 1-4 and 5-8 range pressure test ports.

Pressure test port thread 7/16 -20 UNF

10.

Connect four pressure gauges with scale 0 - 40 bar ( 0 - 600 lbf/in2) 380000552, using the quick release fitting 380000543. Enter the transmission calibration procedure Semi-Powershift transmission Calibrate (21.111). The table below shows the synchroniser calibration stages and at what stage the pressure can be expected to be seen.

NOTE: Due to the operating features of the synchroniser, it is not possible to accurately test the synchroniser control piston pressure during normal tractor operation. The synchroniser will only take the required pressure to move and then the pressure will be cut. This would be seen only as a momentary blip on a pressure gauge. Therefore the following procedure, using the calibration mode, should be used to determine if full pressure is being achieved.

MOIL12TR00789AA

Step START 1 2 3 4 5 6 7 8 END

Forward (F) 18** 0 0 0 0 0-5* 18** 0 0 0

Synchroniser pressures (bar) 1-4 Range Reverse (R) 0 0 0 0-5* 0 18** 0 0-5* 0 18** 0 0 0 0 0 0 0 0 0 0

5-8 Range 18** 0 0 0 0 0 0 0-5* 18** 0

* This pressure slowly increases to overcome the synchroniser detent position and may not be noticed on the pressure gauge. ** This pressure increases at a faster rate to shift the synchroniser into position.

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Transmission - Semi-Powershift transmission

Transmission housing cover - Remove Transmission Top Cover. WARNING Heavy object! ALWAYS use a hoist or get assistance to lift the component. Failure to comply could result in death or serious injury. W0086A

Remove the cab mat and floor. Disconnect the cables from the forward, reverse, 1-4 and 5-8 PWM valves and the position potentiometers on the synchronisers. Disconnect the hydraulic oil supply tube. Remove the transmission top cover retaining bolts (1). Remove the transmission top cover.

MOIL12TR00791AA

MOIL12TR00790AA

Remove the transmission top cover retaining bolts (1). Remove the transmission top cover.

Next operation: Transmission housing cover - Disassemble (21.111).

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Transmission - Semi-Powershift transmission

Transmission housing cover - Assemble Transmission Top Cover. Prior operation: Transmission housing cover - Visual inspection (21.111). NOTE: To re-assemble, use all steps in reverse sequence, considering the following: 1.

Coat the piston oil seals with transmission oil prior to assembly. NEW HOLLAND AMBRA MULTI G 134™ HYDRAULIC TRANSMISSION OIL NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL.

Next operation: Adjust the fork positions on their rods (refer to Transmission internal controls - Travel adjust (21.152)) Transmission housing cover - Install (21.111).

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Transmission - Semi-Powershift transmission

Transmission housing cover - Install Prior operation: Transmission housing cover - Assemble (21.111). 1.

Clean and carefully grease the mating surfaces and apply a strip of sealant of approx. 2 mm in diameter, following the pattern shown in the figure.

MOIL12TR00792AA

MOIL12TR00791AA

MOIL12TR00790AA

Install the transmission top cover (1) and tighten the retaining bolts.

Connect the hydraulic oil supply tube. Connect the forward, reverse, 1-4 and 5-8 PWM valve cables (1) and the synchroniser position potentiometers (2). Install the cab floor panel and replace the mat.

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Transmission - Semi-Powershift transmission

Transmission housing cover - Disassemble - Transmission top cover. Prior operation: Transmission housing cover - Remove (21.111). 1.

Remove the two detent assemblies Transmission housing cover - Exploded view (21.111).

Remove the two synchroniser position potentiometers, shaft housings and operating shafts.

Remove the four PWM solenoid valve assemblies.

Remove the 1-4/5-8 shift rail. Remove the circlip and the end cap of the forward/reverse rail. Loosen the shift fork retaining screws. Through the potentiometer housing orifice carefully pry the 1-4/5-8 shift rail from the top cover.

Remove the forward/reverse shift rail. Remove the circlip and the end cap of the forward/reverse rail. Loosen the shift fork retaining screws. Through the potentiometer housing orifice carefully lever the forward/reverse shift rail from the top cover.

Next operation: Transmission housing cover - Visual inspection (21.111).

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Transmission - Semi-Powershift transmission

Transmission housing cover - Visual inspection Transmission Top Cover. Prior operation: Transmission housing cover - Disassemble (21.111). 1.

Thoroughly clean the top cover, ensuring that the oil galleries from the PWM valves to the shift rail pistons are free from any obstructions.

Inspect the shift rails and forks. Replace if bent and in the case of the forks, the fork tips appear excessively worn.

Inspect all the 'O' ring seals. It is advisable to replace all of the 'O' rings as standard practice. If the oil seals on the forward/reverse or 1-4/5-8 pistons appear in anyway damaged or suspect they should be replaced.

Next operation: Transmission housing cover - Assemble (21.111).

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Testing - Tractor does not drive in any gear Test Point Expected Result N° Result 1 Condition Key ON. Is the Instrument Cluster provid- YES Action ing ‘Normal’ Display? Go to test 2 Result 2 Condition Install flow meter into remote, is flow indi- YES Action cated when operated? Go to test 4 Result YES Action Refer to Fault Codes Electronic module - Fault code index (55.640). Result 4 Condition Charge pump warning light illuminated YES Action Go to test 5 5 Condition Result Check pressure in low pressure circuit. Is YES Action pressure 17 - 19 bar (247 - 276 psi)? Go to test 6 3 Condition Are any fault codes displayed

6 Condition Pressure test the transmission clutches. Are pressures okay?

7 Condition Are the connectors on the controller okay?

8 Condition Does the engine rev/min decrease or the engine stalls? 9 Condition Inspect operation of levers for correct preparation. Enter mode H5, is Neutral/start inhibitor switch okay? 10 Condition Key OFF, Key ON, recheck.

Other Result (Possible Cause) Action NO Go to test 3 Action NO Closed centre system fault. Refer to Hydraulic Pressure Testing Pump - Pressure test (35.106). Action NO Go to test 7

Action NO Go to test 8

Action NO Pressure reducing valve fault, or leak in low pressure circuit. Refer to Hydraulic Pressure Testing Pump - Pressure test (35.106). Action Result NO YES Suspect PWM valves. Clean or Action Suspect a mechanical failure replace valves in circuits with inwithin transmission. Seized correct pressures clutches, synchronizers or broken Go to test 10 gear in shaft. Go to test 10 Action Result NO YES Remove refit/repair as required Action Reset ’H8’ and re-calibrate the Go to test 10 controller. Recheck the operation. If still no drive replace controller. Go to test 10 Action Result NO YES Go to test 9 Action Go to pressure testing clutches Action Result NO YES Inspect switch and wiring Action Go to test 10 Go to test 5 Result Action

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Testing - The tractor remains in the range gear but with the following fault: NOTE: - The Powershift transmission works but the engagement sequence is wrong and some gears are missed out Test Point Expected Result NÂ° Result 1 Condition The PWM valve connectors are on the YES Action right solenoid valves Go to test 2 2 Condition Establish the missing gears. From the table below determine the affected clutch. Carry out a pressure test on the clutch (using the procedure described in the section on pressure tests). Is the pressure 17 - 19 bar? 3 Condition Substitute the affected clutch PWM valve and retest for pressure. Is pressure okay?

4 Condition Move the key start switch to OFF then ON, and check again.

Result YES Action Possible mechanical fault on the clutch or gear shafts Go to test 4

Other Result (Possible Cause) Action NO Using the wiring diagram ensure the correct harness connector is on the appropriate PWM solenoid. Go to test 4 Action NO Go to test 3

Action Result NO YES Possible internal leakage within Action Install a new PWM valve on the the transmission example, side plate gasket, Clutch pack housaffected clutch ing, clutch supply tubes. Go to test 4 Go to test 4 Result Action

MOIL12TR00727AA

MOIL12TR00697AA

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Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Testing - The Powershift gears are not progressive or the tractor loses traction during gear changes. NOTE: During work, the tractor stops or may work jerkily. Test Point NÂ° 1 Condition Perform complete transmission calibration. 1) Spring calibration 2) fill time adjustment Is the Powershift performance still poor? 2 Condition Poor transmission declutching progression? 3

Expected Result Result YES Action Go to test 2

Result YES Action Go to test 3 Result Condition Possible fault or contamination on PWM YES valves 3 or 4. Clean or replace and re- Action peat spring calibration. Is the Powershift Go to test 4 performance poor? Result Condition Are only double gear changes not opti- YES mal? (e.g. from 2 to 3 or from 6 to 7, Action Go to test 5 from 3 to 2 r from 7 to 6) Result Condition Possible fault on the PWM valves 1 or 2. YES Clean or replace. Repeat spring calibra- Action tion and fill time adjustment. Is Powershift Go to test 6 performance still poor? Result Condition YES Remove and test the accumulator Action Is accumulator okay? Possible damaged clutch plates. Inspect and replace as required. For further information refer to Clutch Speed clutch - Visual inspection (21.152) Clutch Range clutch - Visual inspection (21.152)) re-calibrate after assembly Go to test 7 Result Condition Move the key start switch to OFF then ON, and check again.

MOIL12TR00727AA

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Other Result (Possible Cause) Action NUMBER Tractor OK Go to test 7

Action NUMBER Go to test 4 Action NUMBER Go to test 7

Action NUMBER Go to test 6 Action NUMBER Go to test 7

Action NUMBER Repair/replace the accumulator adjust the fill time Go to test 7

Action

Transmission - Semi-Powershift transmission

Semi-Powershift transmission - Testing - The tractor works in all gears but with the following fault: NOTE: - The transmission does not hold the gear, does not change gear or the gears crunch when engaging Test Point NÂ° 1 Condition Is the gear completely engaged? Check and adjust the control lever tie-rod if required. Fault fixed? 2 Condition Using the service diagnostic switch, select mode H9 Channel 48, Clutch pedal display. Does the display go from 4480 mV with the pedal released to 600 mV with the pedal depressed?

Expected Result Result YES Action Go to test 5 Result YES Action Go to test 3

Result YES Action Possible mechanical transmission fault, check the detents in the transmission cover, if no fault is found it is possible that the synchronisers are worn or that there is too much axial play in the transmission components Go to test 5 Result 4 Condition Test affected clutch pack PWM with the YES PWM valve coil removed from the valve. Action Replace the PWM valve with one Is the pressure indicated? of known performance. If there is still pressure, possible internal leakage or faulty side plate gasket. Go to test 5 5 Condition Result Move the key start switch to OFF then ON, and check again. 3 Condition Test the pressure on all clutches. Is the pressure dumped when the clutch pedal is depressed?

Other Result (Possible Cause) Action NUMBER Go to test 2 Action NUMBER Check operation and inspect the clutch pedal switch wiring harness, check that the potentiometer is working, see: Transmission control valve solenoid - Testing (55.024). Go to test 5 Action NUMBER Go to test 4

Action NUMBER Disconnect, inspect and refit controller connectors, if fault still exists replace controller. Go to test 5 Action

Semi-Powershift transmission - Testing The tractor works in all gears but with the following fault: NOTE: - The clutches grind during transmission declutching Test Point NÂ° 1 Condition In 1st (5th) and 3rd (7th) gears only?

Expected Result Result YES Action Go to test 2 Result 2 Condition Pressure test C4 clutch. Is the pressure YES Action 250 - 280 lbf.in2( 17 - 19 bar)? Possible worn clutch plates 3 Condition Result YES In 2nd (6th) and 4th (8th) gears only? Action Go to test 4

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Other Result (Possible Cause) Action NUMBER Go to test 3 Action NUMBER Possible leakage from the clutch gaskets or in the clutch feed circuit Action

Transmission - Semi-Powershift transmission

Test Point Expected Result N° Result 4 Condition Pressure test C4 clutch. Is the pressure ( YES Action 250 - 280 lbf.in2 ( 17 - 19 bar)? Possible worn clutch plates

Other Result (Possible Cause) Action NUMBER Possible leakage from the clutch gaskets or in the clutch feed circuit

Semi-Powershift transmission - Testing The tractor drives in all gears and in all ranges but has the following fault: NOTE: - Transmission is noisy in operation Test Point Expected Result N° Result 1 Condition Is the transmission lube warning light illu- YES Action minated? Go to test 2 Result 2 Condition Fault in the lube supply to transmis- YES sion. Refer to Hydraulic Pressure Testing Action Transmission lubrication valve - Pres- Go to test 3 sure test (21.103). Is the transmission noisy after lube system repair? 3 Condition Result YES Is the oil level correct? Action Go to test 4 4 Condition Result YES Is the correct grade of oil used? Action Suspect failure within transmission, worn bearings, worn or failed parts

Other Result (Possible Cause) Action NO Go to test 3 Action

Action NO Adjust as required and investigate reason for oil loss (leakage) Action NO Drain and refill with correct grade of oil

Semi-Powershift transmission - Testing - Tractor drives in all gears and ranges but has the following fault: NOTE: - Transmission clunks during inching. Test Point N° 1 Condition Perform Clutch spring calibration on C1 and C2 Clutches. Does Transmission still clunk? 2 Condition Perform manual clutch fill time calibration on C1 and C2 clutches. Does transmission still clunk after fill time calibration? 3 Condition Perform clutch pressure test procedure, observing the operation of the C1 and C2 Clutches. Does the operation compare with that described in the pressure testing section? Semi-Powershift transmission - Pressure test (21.111).

Expected Result Result YES Action Go to test 2 Result YES Action Go to test 3 Result YES Action Suspect worn clutches. Examine and replace as required

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Other Result (Possible Cause) Action NO Tractor okay Action NO Tractor okay Action NO Suspect faulty or contaminated PWM Valves, clean or replace as required

Index Transmission - 21 Semi-Powershift transmission - 111 Semi-Powershift transmission - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Semi-Powershift transmission - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Semi-Powershift transmission - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Semi-Powershift transmission - Hydraulic schema (Diagrams 1st gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Semi-Powershift transmission - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Semi-Powershift transmission - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Semi-Powershift transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Semi-Powershift transmission - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Semi-Powershift transmission - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Semi-Powershift transmission - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Semi-Powershift transmission - Testing - The Powershift gears are not progressive or the tractor loses traction during gear changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Semi-Powershift transmission - Testing - The tractor remains in the range gear but with the following fault: . . . . 67 Semi-Powershift transmission - Testing - The tractor works in all gears but with the following fault: . . . . . . . . . . . 69 Semi-Powershift transmission - Testing - Tractor does not drive in any gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Semi-Powershift transmission - Testing - Tractor drives in all gears and ranges but has the following fault: . . . . 70 Semi-Powershift transmission - Testing The tractor drives in all gears and in all ranges but has the following fault: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Semi-Powershift transmission - Testing The tractor works in all gears but with the following fault: . . . . . . . . . . . . 69 Semi-Powershift transmission - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Transmission housing cover - Assemble Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Transmission housing cover - Disassemble - Transmission top cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Transmission housing cover - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Transmission housing cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Transmission housing cover - Remove Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Transmission housing cover - Visual inspection Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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Transmission - 21 Semi-Powershift transmission external controls - 133

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Transmission - 21 Semi-Powershift transmission external controls - 133

FUNCTIONAL DATA Transmission control valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Transmission control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Transmission - Semi-Powershift transmission external controls

Transmission control valve - Overview

MOIL12TR00783GA

Identification of pressure test ports on remote valves and solenoid valves 1 C4 clutch pressure test port 3 C3/C4 clutch lubrication pressure testing pressure test port 5 Lubrication pressure test port 7 C2 clutch pressure test port 9 C1 clutch pressure test port 11 Oil temperature sender 13 Clutch C2 PWM valve 15 Clutch C4 PWM valve

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Transmission - Semi-Powershift transmission external controls

Transmission control valve - Remove NOTE: The following procedure treats the transmission as removed from the tractor. It is possible to remove the control valve assembly from the transmission without removing the transmission from the tractor. The surrounding oil supply tubing, accumulator and other peripheral hardware must in any case be removed. NOTE: It should be noted that unless contaminant is suspected to be within the control valve cover oil galleries or there is a suspected fault within the lubrication control valve, it is not necessary to remove the valve cover to remove any of the PWM solenoids. NOTE: When removing the valve and connecting nuts and bolts, avoid the entry of external contaminants in the transmission at all costs. If necessary steam clean the outside of the control valve area before proceeding to remove the valve assembly.

Removing the control valve 1.

Remove the surrounding oil supply tubing, accumulator and other peripheral hardware. Remove the control valve cover retaining bolts (1).

MOIL12TR00793AA

MOIL12TR00794AA

MOIL12TR00754AA

Using the separating holes (1), remove the transmission control valve from the transmission housing.

Remove the spring holding the high/low gear range control rod in place (1), the poppet ball actuator (2) and the poppet ball (3).

Next operation: Transmission control valve - Visual inspection (21.133).

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Transmission - Semi-Powershift transmission external controls

Transmission control valve - Install Prior operation: Transmission control valve - Remove (21.133) Transmission control valve - Visual inspection (21.133). 1.

Install the high/low gear range poppet ball (3), the poppet ball actuator (2) and the retaining spring on the high/low gear range engagement rod (1).

MOIL12TR00754AA

MOIL12TR00796AA

MOIL12TR00793AA

Clean and carefully grease the mating surfaces and apply a strip of sealant of approx. 2 mm in diameter, following the pattern shown in the figure.

Install the control valve cover and tighten the retaining bolts to the specified torque value. Install the surrounding oil supply tubing, accumulator and other peripheral hardware. Top up the gear an d rear transmission with oil NEW HOLLAND AMBRA MULTI G 134â&#x201E;˘ HYDRAULIC TRANSMISSION OIL NEW HOLLAND AMBRA MULTI Gâ&#x201E;˘ HYDRAULIC TRANSMISSION OIL.

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Transmission - Semi-Powershift transmission external controls

Transmission control valve - Assemble Assemble following the disassembly procedure in the reverse order. Before installing, make sure that the O-rings on all solenoid valve assemblies are in good condition. Before reassembling, spread a thin layer of clean transmission oil NEW HOLLAND AMBRA MULTI G 134â&#x201E;˘ HYDRAULIC TRANSMISSION OIL NEW HOLLAND AMBRA MULTI Gâ&#x201E;˘ HYDRAULIC TRANSMISSION OIL on all components. 1.

Tighten the bolts to the torque of 27 Nm ( 20 lbf.ft).

MOIL12TR00731AA

Control valve assembly 1 Lubricating oil delivery inlet fitting 3 Transmission oil temperature sensor 5 C2 clutch PWM valve and solenoid valve assembly 7 C4 clutch PWM valve and solenoid valve assembly

2 Supply/pressure regulated oil inlet fitting 4 C1 clutch PWM valve and solenoid valve assembly 6 C3 clutch PWM valve and solenoid valve assembly

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Transmission - Semi-Powershift transmission external controls

Transmission control valve - Disassemble Absolute cleanliness is essential during disassembly and reassembly of the control valve. Ensure the working area is clean and not likely to be contaminated by other working operations being performed alongside. It is recommended that only a clean, dust free environment is used for the overhaul.

Lubrication valve removal and disassembly 1.

Place the control valve face down on a clean surface and remove the retaining bolts retaining the lubrication valve assembly to the side cover. Carefully slide out the lubrication valve, referring to the position of the seal between the two castings. Remove the terminal caps and slide out the spools and springs as shown in Figure 2.

MOIL12TR00795AA

1 3 5 7 2.

Dowel Dowel Side cover C3/C4 clutch delivery pipes

2 O-Ring 4 High/low gear range stop 6 Lubrication valve

Clean the valve head in suitable solvent and dry with compressed air.

NOTE: When cleaning, check to see if any contaminants leak out which could have caused the valve to block or stick. 3.

Examine the valves and bores for wear or damage, replace parts as necessary.

Assemble following the disassembly procedure in the reverse order. Spread a thin layer of clean transmission oil type NEW HOLLAND AMBRA MULTI G 134â&#x201E;˘ HYDRAULIC TRANSMISSION OIL NEW HOLLAND AMBRA MULTI Gâ&#x201E;˘ HYDRAULIC TRANSMISSION OIL on all the components immediately before re-assembling.

Before assembling the lubrication valve on the cover, check that the mating surfaces are clean and that a replacement seal has been fitted. Do not use a liquid gasket sealant between these surfaces.

Valve cover disassembly 6.

Remove the four PWM solenoid valves and the oil temperature sender.

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Transmission - Semi-Powershift transmission external controls

MOIL12TR00732AA

Lubrication valve assembly 1 Lubrication pressure relief valve 3 Selector valve ball

2 Lubrication control valve spool 4 Spring ( 220 lb) and valve spool operating piston

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Transmission - Semi-Powershift transmission external controls

Transmission control valve - Visual inspection Prior operation: Transmission control valve - Remove (21.133)bolt. NOTE: When cleaning, check to see if any contaminants leak out which could have caused the valve to block or stick. 1.

Clean the cover in suitable solvent and dry carefully.

Carefully examine the cover for hairline cracks or other damage which may have caused oil leakage. Replace the cover if any damage or cracks are found, do not attempt a repair.

Clean the complete PWM valve assemblies, less the solenoids, in a suitable cleaning solvent. It is not recommended to disassemble the PWM valves further to clean. If the performance of the valve is suspect and no contaminant is found during cleaning, but the solenoid is within specification, the valve should be replaced with a new one.

Next operation: Transmission control valve - Install (21.133)bolt.

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Index Transmission - 21 Semi-Powershift transmission external controls - 133 Transmission control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Transmission control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Transmission control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Transmission control valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Transmission control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Transmission control valve - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Transmission - 21 Semi-Powershift transmission internal components - 152

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Transmission - 21 Semi-Powershift transmission internal components - 152

SERVICE Clutch Remove - Front section removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove - Rear section disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble - Front section disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassemble - Rear section disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble - C1/C2 Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Remove C3/C4 clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Visual inspection C3/C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Assemble - C3/C4 Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Transmission internal controls Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Gears Remove - Central section removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Assemble - Central section assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Disassemble Center Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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Transmission - Semi-Powershift transmission internal components

Clutch - Remove - Front section removal. Prior operation: Semi-Powershift transmission - Service instruction (21.111) Semi-Powershift transmission - Disassemble (21.111) is exceeded.

MOIL13TR00031FA

1 C1/C2 clutch support shaft 3 Clutch sealing rings 5 C1 clutch roller bearing 7 C1/C2 clutch assembly 9 Front bottom support shaft 11 Lubrication oil flap 1.

2 â&#x20AC;?O-Ringâ&#x20AC;? seal 4 Polyamide thrust washer 6 C1 clutch driven gear (34 teeth) 8 Support shaft roller bearing 10 Support shaft roller bearing 12 Front cover plate

Rotate the transmission to a vertical position. Remove the retaining bracket (1) on the oil transfer pipe and the lubrication oil supply pipe (2).

MOIL12TR00777AA

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Transmission - Semi-Powershift transmission internal components

Reposition the oil transfer tubes back into the front cover distribution block.

MOIL12TR00797AA

MOIL12TR00798AA

MOIL12TR00799AA

MOIL12TR00775AA

Remove the front cover retaining bolts.

Remove the C1/C2 clutch support manifold retaining bolts (1). Remove the C1/C2 clutch support manifold (4). Install two bolts into the separating holes (3) and remove the front cover plate (2) from the transmission housing.

Remove the expansion valve (1) and the O-rings (2).

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Transmission - Semi-Powershift transmission internal components

Remove the flap (1) and the front roller bearing (4) from the front lower support shaft (3). Remove the roller bearing (2).

NOTE: The front roller bearing (4) and the flap (1) can stay on the front cover plate.

MOIL12TR00773AA

MOIL12TR00772AA

MOIL12TR00771AA

Remove the C1/C2 clutches (3), the driven gear (2) and the lower front support shaft (1).

Remove the drive shaft/PTO (1).

Remove the steel thrust washer (1) and the roller bearing from the PTO input shaft (2).

MOIL12TR00800AA

Next operation: Clutch Range clutch - Disassemble (21.152) is exceeded.

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Transmission - Semi-Powershift transmission internal components

Clutch - Remove - Rear section disassembly. Prior operation: Semi-Powershift transmission - Service instruction (21.111).

MOIL13TR00035FA

1 C3 clutch 3 C4 clutch driven gear (41 or 37 teeth) 5 Driven shaft 7 Hi/low gear range synchroniser 1.

2 4 6 8

C4 clutch C3/C4 clutch support assembly Low gear range gear (65 teeth) Cluster gear

Rotate the transmission until the rear part is in a vertical position .Using a suitable lever (5), raise the output shaft assembly (1) to enable the installation of the circlip (2). Remove the circlip (2), the 'D' washer (3) and the roller bearing thrust washer (4).

MOIL13TR00923AA

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Transmission - Semi-Powershift transmission internal components

Remove the rear cover retaining bolts (1).

MOIL13TR00924AA

MOIL12TR00762AA

MOIL12TR00760AA

MOIL12TR00759AA

Remove the rear cover assembly.

Unscrew the lock nut (1) and remove the retaining bolt (2) from the high/low gear range selector fork rod. Remove the high/low gear range selector fork rod (3).

Remove the output shaft, high/low gear range synchroniser and coupling fork as a single assembly.

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Transmission - Semi-Powershift transmission internal components

Remove the C3 clutch output shaft.

MOIL12TR00758AA

MOIL12TR00757AA

MOIL13TR00015AA

Remove the C3/C4 clutch and oil supply manifold assembly.

NOTE: If you are working without the right equipment, perhaps with the transmission resting on a fixed and not a swivel surface, so that you cannot rotate the transmission to remove the parts see Semi-Powershift transmission - Service instruction (21.111), it is particularly difficult to remove the clutch assembly with the manifold; therefore proceed following the indications in the figure below.

From the rear of the transmission housing, use an appropriately sized hexagonal wrench to remove the three retaining bolts from the end of the lubrication - clutch pressure manifold, then put the terminal (1) to one side and remove the clutch complete with the inner manifold.

Unscrew the retaining bolts (1) and remove the selector actuator (5). Remove the woodruff key (4), the retaining pin (2) and remove the shaft (3). Remove and inspect any bearings which may still be in the transmission housing.

MOIL12TR00756AA

Next operation: Clutch Speed clutch - Disassemble (21.152).

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Transmission - Semi-Powershift transmission internal components

Clutch - Disassemble - Front section disassembly. Prior operation: Clutch Range clutch - Remove (21.152) is exceeded.

MOIL13TR00032FA

1 C1 clutch driven gear (34 teeth) 3 C2 clutch 5 Lower shaft

2 C1 clutch 4 Lower shaft bearing 6 Lower shaft bearing

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00037GA

Sectional view - C1/C2 clutches 1 Clutch support 3 C2 clutch 5 Drive shaft/PTO

2 C1 clutch 4 C1 clutch driven gear

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Transmission - Semi-Powershift transmission internal components

C1 Clutch Disassembly 1.

Remove the roller bearing (2) and the driven gear (3) from the centre of the C1 clutch (1).

MOIL13TR00016AA

MOIL13TR00017AA

MOIL13TR00018AA

MOIL13TR00019AA

Remove the clutch hub (1) from the C1/C2 clutch housing (2).

Remove the steel thrust washer (1).

NOTE: The inner surface of the thrust washer is raised (2).

Remove the snap ring (1) with a suitable lever.

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Transmission - Semi-Powershift transmission internal components

Remove the end plate (1).

MOIL13TR00020AA

MOIL13TR00023AA

MOIL13TR00021AA

Remove the five friction plates, the five pressure springs and the five steel disks (1) . Inspect the clutch friction and steel plates for excessive wear. The friction plate material should have a clear distinctive pattern. All plates should be flat without warping and there should not be excessive discolouration. Use new parts as necessary. Inspect the pressure springs for distortion or discolouration. Compare each spring shape and height with a new spring. Use new parts as necessary.

NOTE: It is not possible to remove the components (1) as a complete assembly.

C2 Clutch Disassembly 7.

Remove the snap ring (1) with a suitable lever.

Remove the end plate (1), the central clutch hub (2) and the steel thrust washer (3).

MOIL13TR00022AA

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Transmission - Semi-Powershift transmission internal components

NOTE: It is not possible to remove the components (1) as a complete assembly.

10.

MOIL13TR00023AA

MOIL13TR00024AA

MOIL13TR00025AA

MOIL13TR00027AA

WARNING Spring under tension! Compressed springs have potentially dangerous stored energy. Always assemble and disassemble properly. Failure to comply could result in death or serious injury. W0356A

Assembly/disassembly of the C1/C2 clutches Using a suitable hydraulic press (2) and the special tool 380001155 (1), compress the piston return spring retainer (4) to be able to remove the snap ring (3). 11.

12.

Remove the piston return spring retainer snap ring. Release the hydraulic press and remove the piston return spring assembly. Repeat steps 1 to 3 for the C2 clutch housing.

Remove the pistons using compressed air at a pressure of no more than 3 bar ( 50 lbf/in2) in the oil delivery coupler (1) on the C2 clutch control piston and in the oil delivery coupler (2) of the C1 clutch piston.

NOTE: Install the C1/C2 clutch support manifold (2) temporarily in order to be able to use the compressed air.

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00036FA

1 3 5 7

Clutch Housing Belleville spring Locking ring Piston oil seal

2 Pistons 4 Piston adaptor 6 Return spring assembly

Next operation: Clutch Range clutch - Visual inspection (21.152) is exceeded.

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Transmission - Semi-Powershift transmission internal components

Clutch - Visual inspection Prior operation: Clutch Range clutch - Disassemble (21.152). NOTE: The Belleville spring is concave in shape. Take note of the assembly position when removing. 1.

Inspect the piston inner and outer components for scoring or damage. Inspect the piston belleville washer for distortion. Use new parts as necessary.

Inspect the clutch housing for scratches, scores, excessive wear and piston scuffing. Use new parts as necessary.

Remove the piston outer oil seals from the clutch pistons.

Remove the piston inner oil seals and oil seal energisers from the clutch housing.

Inspect the clutch driven hubs for wear or damage. Use new parts as necessary.

Inspect the front lower shaft gears and gear teeth for damage. Use new parts as necessary.

Inspect the clutch engagement spring assemblies for cracked coils or distortion. Use new parts as necessary.

Inspect the C1 and C2 clutch spring assembly loaded height as shown, or compare with a new item. Replace the spring assembly as required.

MOIL12TR00906AA

1 Load splitter (flat disk) 3 Piston return spring assembly F = 1630 N (366.4 lb) Âą 90 N (20.2 lb) Piston return spring assembly

2 Weight (or load) 4 Base Plate D â&#x2030;&#x2C6; 18.8 mm (0.7 in) Base Plate

Next operation: Clutch Master clutch - Assemble (21.152).

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Transmission - Semi-Powershift transmission internal components

Clutch - Disassemble - Rear section disassembly Prior operation: Clutch Speed clutch - Remove (21.152) is exceeded.

MOIL13TR00035FA

Drive Line Components - Rear Section 1 C3 clutch 3 C4 clutch driven gear (41 or 37 teeth) 5 Driven shaft 7 Hi/low gear range synchroniser

2 4 6 8

C4 clutch C3/C4 clutch support assembly Low gear range gear (65 teeth) Cluster gear

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00030FA

C4 clutch driven gear, gear bearing, C3 clutch driven gear bearing and polyamide thrust washer 1 Manifold 3 C4 clutch driven gear 5 C4 clutch driven gear front bearing 7 Rear bearing between the support shaft and the C3 clutch driven gear 9 Manifold retaining bolts and washers

2 4 6 8

Polyamide thrust washer C3/C4 clutch assembly Support shaft C4 clutch driven gear rear bearing

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00038GA

Sectional view - C3/C4 clutches 1 C3 clutch terminal plate 3 Piston external oil seals 5 Steel washer 7 Clutch disk bearing retainer 9 C4 clutch driven gear roller bearing 11 Polyamide thrust washer 13 Belleville springs 15 Locking ring 17 Clutch disk bearing retainer 19 Support shaft sealing rings 21 Roller bearing

2 C3 clutch piston 4 C4 clutch piston 6 C4 clutch terminal plate 8 C3 clutch driven gear roller bearing 10 Polyamide thrust washer 12 Belleville spring snap ring stop 14 Piston internal oil seals 16 Belleville spring retaining ring 18 Locking ring 20 Support shaft roller bearing 22 Clutch disk bearing retainer

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Transmission - Semi-Powershift transmission internal components

Clutch - Assemble - C1/C2 Clutches. Prior operation: Clutch Range clutch - Disassemble (21.152) Clutch Range clutch - Visual inspection (21.152). NOTE: Make sure that the seal lip of the oil seal is facing the inner or rear surface of the piston (2). 1.

Install the external oil seal (1) on the C1 clutch piston. Repeat this step for the C2 clutch piston.

MOIL12TR00907AA

MOIL13TR00026AA

Install the C1 clutch piston inner oil seal energiser into the groove on the clutch housing. Repeat this step for the C2 clutch piston inner seal energiser.

NOTE: Make sure that the oil seal fits correctly in its seat and that the seal lip is not folded in the groove.

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00033FA

Installation and finishing of the inner seals 1 Special tool 380001150 (tapered sleeve expander) 3 Special tool 380200316 (re-sizer) 5 Seal positioned in the groove on the end of the turnbuckle 7 Seal groove with turnbuckle already installed 3.

2 Special tool 380001148 (grip) 4 C1/C2 clutch housing assembly 6 Seal positioned in the expander

Lubricate the inner oil seal of the piston and the special tool 380001150 (1) with petroleum jelly and place the expander sleeve in the centre of the clutch housing (4) with the oil seal (6) on the sleeve, as shown.

NOTE: Perform the operation quickly so that the oil seal is not subjected to the stretching action for too long. 4.

Press the inner oil seal of the piston on the tapered end, allowing it to fall on the turnbuckle, already positioned in the clutch housing (5).

Place the clutch housing with the inner oil seal installed in a suitable cooling device for approximately 30 minutes.

NOTICE: When the implement is positioned on the oil seal, make sure it slides freely and smoothly. When the process is completed, inspect the oil seal to ensure that no damage has occurred. 6.

Ensure the oil seal is lubricated. Assemble the re-sizer special tool 380200316 (3) onto the handle of special tool 380001148 (2), so that the smaller diameter is at the opening. Lubricate the re-sizer with petroleum jelly and using the handle, firmly push the re-sizer over the oil seal to compress and re-size the oil seal. 47538922 29/05/2013

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Transmission - Semi-Powershift transmission internal components

Place with clutch housing with the special tool still installed in position in a suitable cooling device for approximately 30 minutes.

Repeat the installation and re-sizing process on the second clutch piston inner oil seal.

MOIL13TR00034FA

Installation of the Pistons into the C1/C2 Clutch Housing 1 Piston sizing sleeve, special tool 380200315 3 Piston striker, special tool 380001151

2 Stroke piston 4 Piston outer seal

Lubricate the C1 piston inner oil seal inside the clutch housing with petroleum jelly and check that the oil seal is resized.

10.

Position the piston sizing sleeve, special tool 380200315 (1), on the top of the C1 clutch housing and lubricate the tool inside with petroleum jelly.

NOTICE: Install the piston by hand only to avoid damaging the oil seal. 11.

Position the piston (2) in the sizing sleeve and using the piston striker, special tool 380001151 (3), insert the piston in the housing smoothly and firmly.

12.

Remove the special tools 380001151 (3) and 380200315 (1).

13.

Position the piston Belleville washer on top of the main piston making sure the outer edge of the Belleville is facing upwards and that the inner diameter is resting on the piston. Install the outside of the piston, see Clutch Range clutch - Disassemble (21.152).

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Transmission - Semi-Powershift transmission internal components

14.

Repeat the piston installation process on the second clutch piston.

15.

Assemble the clutch return spring assembly (4), onto the clutch housing and using a suitable hydraulic press (2), and spring compressor special tool 380001155 (1), compress the spring assembly and install the snap ring (3). Release the hydraulic press and remove the special tool. Repeat the above procedure for the second clutch.

16.

MOIL13TR00024AA

MOIL13TR00027AA

MOIL13TR00014AA

Check the piston oil seals using compressed air at a pressure of no more than 3 bar ( 3,05 Kgm/cm2) in the oil delivery coupler (1) of the C2 clutch control piston and in the oil delivery coupler (2) of the C1 clutch piston. Make sure the pistons have no signs of leakage.

NOTE: Temporarily install the C1/C2 clutch support manifold (2) to allow compressed air to be applied. Spread transmission oil on the pistons in order to identify any leakages.

C1/C2 clutch support manifold inspection and assembly 17.

The support shaft also contains rubber adaptors (3) and (4), these adaptors join the C1/C2 clutch oil transfer tubes and the front lower shaft lubrication oil supply tube. Check that the components show no signs of wear or damage, clean them carefully and re-assemble, replace if required. 1.

Support shaft.

O-ring seal.

Rubber adaptor.

Lower shaft lubrication rubber adaptors.

Ring gasket.

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Transmission - Semi-Powershift transmission internal components

18.

19.

The front cover (1) contains rubber adaptors (3) and (4) similar to those on the support shaft. It fits on the C1/C2 clutch oil transfer pipes and the front lower shaft lubrication oil supply tube. Check that the components show no signs of wear or damage, clean them carefully and re-assemble, replace if required. 1.

Front cover.

Rubber adaptors.

Lower shaft lubrication rubber adaptor.

MOIL13TR00013AA

MOIL13TR00012AA

Near the above adaptors, on the front cover (1) there are four caps (2) and relative seals held in place by a pin (4). This is held in place by two snap rings (3). Check that the components are not worn or damaged, clean them carefully and re-assemble. 1.

Front cover.

Plugs.

Snap rings.

Cap retaining pin.

C1/C2 Clutch Support Manifold Inspection and Assembly 20.

21.

Remove the PTO input shaft oil seal (1) from the C1/C2 clutch support manifold (2). Install a new oil seal by gently pressing it into the centre of the support shaft (ensure the oil seal lip is facing inwards towards the transmission). Remove and discard the four annular groove seal rings (3) and check that the shaft is not worn or damaged. Replace parts as necessary. Install new annular groove sealing rings (3) to the support manifold. Ensure the annular groove sealing ring ends are correctly positioned.

MOIL13TR00918AA

MOIL13TR00919AA

Inspect the PTO input shaft (1) for damage, evidence of seizure, pick-up etc. Replace the components as required. Inspect the splined areas for damage. Replace parts as necessary. Make sure all of the oil galleries are thoroughly clean. Replace the lubrication oil seal (2). Inspect the steel washer (3), snap rings and their grooves for distortion and damage. Replace parts as necessary.

NOTE: It is important the lubrication oil seal (2) is held down in its groove during re-assembly. If the oil seal is damaged, lubrication oil will not be correctly distributed.

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00028FA

2 Friction plate x 5 4 Separating spring x 5 6 Piston Return Spring Assembly 8 Outer piston half 10 Piston outer seal 12 Snap ring

1 Snap ring 3 Steel plate x 5 5 Clutch hub 7 Washer belleville 9 C1/C2 clutch housing 11 Inner piston half 13 End plate 22.

Install the steel plates (4), friction plates (3) and the separating springs (12).

NOTE: Make sure the openings on the separator springs are all aligned. NOTE: Make sure the last separating spring does not become hooked in the snap ring groove. 23.

Install the end plate (2).

24.

Apply a small amount of pressure to the end plate and install the retaining snap ring (1).

25.

Repeat the above procedure for the second clutch.

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00029FA

C1/C2 Clutch Hubs and Gears - Exploded View 1 Thrust washer 3 C1 clutch output gear 5 Snap ring 7 Steel washer (note: step on inner face) 9 Steel washer (note: step on inner face) 11 C2 end plate

2 Needle bearing 4 C1 clutch hub 6 C1 clutch end plate 8 C1/C2 clutch housing 10 C2 clutch hub 12 Snap ring

26.

Install the C2 clutch hub (10) into the C2 clutch housing (8).

27.

Install the steel washer (9) (ensure the step on the inner face is against the piston return spring assembly of the C1 clutch).

28.

Install the C1 clutch hub (4) into the C1 clutch housing.

Next operation: Semi-Powershift transmission - Service instruction (21.111).

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Transmission - Semi-Powershift transmission internal components

Clutch - Remove C3/C4 clutches 1.

Press down the end plate (1) and use appropriately sized seeger pliers to remove the seeger (2), then release the end plate.

MOIL13TR00225AA

MOIL13TR00230FA

C3 clutch plates and friction plates - assembly order 1 3 5 7

2 4 6 8

C3 clutch hub End plate snap ring Separating springs x 10 Separating spring anti-rotation pin

Remove from the C3 clutch the end plate (4), the clutch hub (1), the friction plates (2), the separating springs (5) and the steel plates (6).

Recover the pin (7) that stops the separation springs from rotating.

Friction plates x 10 End plate Steel plates x 10 C3/C4 clutch housing

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Transmission - Semi-Powershift transmission internal components

Rotate the assembly by 180 Â°

Remove the manifold retaining bolts (1) and the washers (2). Remove the manifold (3). Remove the polyamide thrust washer (4).

MOIL13TR00215AA

MOIL13TR00216AA

MOIL13TR00217AA

Remove the C4 clutch driven gear (1) and relative rear roller bearing (2).

Using suitable snap ring pliers, remove the snap ring (1).

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00231FA

C4 clutch pressure plate ring, hub, friction plates and steel plates - exploded view 1 Friction plates x 10 3 End plate 5 Steel plates x 10 7 Lubricating oil gasket Snap ring retainer 9 Steel washer

2 Snap ring 4 Separating springs x 10 6 Separating spring anti-rotation pin 8 Clutch hub 10 C3/C4 clutch housing External piston oil seal

Remove the C4 clutch end plate (3), clutch hub (8), friction plates (1) steel plates (5) and the steel washer (9).

Remove the front roller bearing from the C4 clutch driven gear (1), the steel thrust washer (2) and the C4 clutch support shaft roller bearing (3) from the support shaft (4). Rotate the clutch assembly with the support shaft facing downwards.

MOIL13TR00218AA

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Transmission - Semi-Powershift transmission internal components

10.

11.

Remove the clutch support shaft front bearing (4) and the retaining snap rings (2) and (3) from the C4 clutch housing (1).

MOIL13TR00226AA

MOIL13TR00219AA

Remove the support shaft (1) from the bearing, sliding it out from the C4 clutch side of the housing.

NOTE: The support shaft must be removed from the C4 clutch side to avoid damaging the sealing rings (2).

12.

Using a suitable hydraulic press (2) and the special tool 380001155 (1), press the return Belleville springs on the clutch piston and remove the snap ring (3) . Release the hydraulic press and collect the Belleville washers and the snap ring retainer. Repeat the above procedure for the second clutch piston return Belleville washers.

NOTE: The stop plate is shaped to ensure the snap ring is locked.

13.

MOIL13TR00220AA

MOIL13TR00221AA

Remove the pistons using compressed air at a pressure of max. 3 bar (43.5 psi) in the oil delivery couplings (2) on the clutch control piston.

NOTE: Every piston has two supply holes. Apply compressed air to one of the holes and seal the other (1) .

Next operation: Clutch - Visual inspection (21.152)series tractor.

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Transmission - Semi-Powershift transmission internal components

Clutch - Visual inspection C3/C4

MOIL13TR00232FA

Piston Return Spring and Retainer - Exploded View 1 3 5 7 1.

Locking ring Belleville washers x 102 Pistons Snap ring groove

2 4 6 8

Snap ring retainer Flat washer Piston outer oil seal C3/C4 clutch body

Inspect each of the belleville spring washers for cracks and deformation. Assemble the Belleville springs to form a stack (2). Measure the height as shown in figure (1). The height should be approximately 30 mm. If the specified height is incorrect, replace parts as necessary.

NOTE: Alternatively compare the measured height with that of new items. 2.

Check that the splined areas of the input hub and the output gear are undamaged.

MOIL13TR00041AA

Inspect the clutch driven hubs for wear, damage or pitting.

Install a new lubrication oil seal into the groove of the C4 clutch hub, ensure that it is correctly seated.

Ensure all of the oil galleries are free and thoroughly clean.

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Transmission - Semi-Powershift transmission internal components

Inspect all snap rings and their grooves for deformation and damage.

Check the clutch friction and steel plates for excessive wear, the friction plate material should have a clear distinctive pattern. All plates should be flat without warping and there should not be excessive discolouration.

Lubricate all the components with gear oil NEW HOLLAND AMBRA MULTI G 134™ HYDRAULIC TRANSMISSION OIL NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL before reassembling.

8. Inspect the pressure springs for distortion or discolouration. Compare each spring shape and height with a new spring. Use new parts as necessary.

10.

Make sure that all components are lubricated with gear oil NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL

11.

Using a special punch, remove the concave washers (1), check their condition and direction.

NOTE: when installing the concave washers (8) the raised surface of the washer must be facing out.

MOIL13TR00227AA

Next operation: Clutch - Assemble (21.152)series tractor.

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Transmission - Semi-Powershift transmission internal components

Clutch - Assemble - C3/C4 Clutches. Prior operation: Clutch Speed clutch - Disassemble (21.152) Clutch Speed clutch - Visual inspection (21.152). NOTE: Make sure that the seal lip of the oil seal is facing the inner or rear surface of the piston (2). 1.

Install the external oil seal (1) on the C3 clutch piston. Repeat this step for the C4 clutch piston.

MOIL13TR00042AA

MOIL13TR00222AA

Install the C3 clutch piston inner oil seal energiser into the groove on the clutch housing. Repeat this step for the C4 clutch piston inner seal energiser.

NOTE: Make sure that the oil seal fits correctly in its seat and that the seal lip is not folded in the groove.

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00033FA

Installation and finishing of internal oil seals 1 Special tool 380001149 (tapered sleeve expander) 3 Special tool 380001148 (grip) 5 C3/C4 clutch housing 7 Oil seal energiser in place in the groove 3.

2 Special tool 380200316 (re-sizer) 4 Piston internal oil seal in the relative groove 6 Piston internal oil seal on the tapered sleeve expander

Lubricate the inner oil seal of the piston and the special tool 380001149 (1) with petroleum jelly and place the expander sleeve in the centre of the clutch housing (6) with the oil seal on the sleeve, as shown.

NOTE: Perform the operation quickly so that the oil seal is not subjected to the stretching action for too long. 4.

Press the inner oil seal of the piston on the tapered end, allowing it to fall on the turnbuckle, already positioned in the clutch housing.

Place the clutch housing with the inner oil seal installed in a suitable cooling device for approximately 30 minutes.

NOTICE: When the implement is positioned on the oil seal, make sure it slides freely and smoothly. When the process is completed, inspect the oil seal to ensure that no damage has occurred. 6.

Ensure the oil seal is fully lubricated. Assemble the re-sizer, special tool 380200316 (2), on the grip of the special tool 380001148 (3), with the larger diameter facing the opening. Lubricate the re-sizer with petroleum jelly and using the handle, firmly push the re-sizer over the oil seal to compress and re-size the oil seal.

Place with clutch housing with the special tool still installed in position in a suitable cooling device for approximately 30 minutes. 47538922 29/05/2013

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Transmission - Semi-Powershift transmission internal components

Repeat the installation and re-sizing process on the second clutch piston inner oil seal.

MOIL13TR00034FA

Installing the pistons in the C3/C4 clutch housing 1 Piston sizing sleeve, special tool 380001152 3 Piston striker, special tool 380001151

2 Stroke piston 4 Piston oil seal

Lubricate the piston inner oil seal inside the clutch housing with petroleum jelly and check that the oil seal is resized.

10.

Position the piston sizing sleeve, special tool 380001152 (1), on the top of the clutch housing and lubricate the tool inside with petroleum jelly.

11.

Position the piston (2) in the sizing sleeve and using the piston striker, special tool 380001151 (3), insert the piston in the housing smoothly and firmly. Remove the sizing sleeve and the piston striker.

NOTICE: Install the piston by hand only to avoid damaging the oil seal. 12.

Repeat the piston installation process on the second clutch piston.

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Transmission - Semi-Powershift transmission internal components

Adjusting piston clearance for C3/C4 clutches NOTE: Assemble the support shaft (1) in the clutch assembly from the C4 end so as not to damage the sealing rings (2). 13.

14.

Install the support shaft (1), with new sealing rings (2).

MOIL13TR00219AA

MOIL13TR00226AA

Install the clutch support shaft front bearing (4) and the retaining snap rings (2) and (3) in the C4 clutch housing (1).

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00232FA

Piston return spring and retainer - Exploded view 1 3 5 7

Snap ring Belleville washers x 102 Stroke piston Snap ring groove

15.

2 4 6 8

Snap ring retainer Flat washer Piston outer oil seal C3/C4 clutch body

Using an appropriate hydraulic press (2) and the special tool 380001155 (1), press the return Belleville springs on the piston and install the retaining snap ring (3). Release the hydraulic press. Repeat the process on the second clutch piston return Belleville springs.

NOTE: The stop plate is shaped to ensure the snap ring is locked.

MOIL13TR00220AA

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Transmission - Semi-Powershift transmission internal components

16.

Check the piston oil seals using compressed air at a pressure of max. 3 bar ( 50 lbf/in2) in the C3/C4 clutch oil delivery couplings. Make sure that the pistons show no sign of leakage. Turn the clutch assembly over with the support shaft facing downwards.

NOTE: Spread transmission oil on the pistons in order to identify any leakages.

MOIL13TR00221AA

MOIL13TR00230FA

C3 clutch plates and friction plates - assembly order 1 3 5 7

C3 clutch hub End plate snap ring Separating springs x 10 Separating spring anti-rotation pin

2 4 6 8

Friction plates x 10 End plate Steel plates x 10 C3/C4 clutch housing

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Transmission - Semi-Powershift transmission internal components

17.

18.

Install the hub (1) in the clutch housing (2).

MOIL13TR00223AA

MOIL13TR00228AA

Install the first steel plate (4), insert the pin (1) in its seat, insert the first friction plate (3) and the first separating spring (2), with the pin in the spring housing.

NOTE: On the steel plate (2) , there is a much deeper space between the teeth (see area (4)) where the pin housing is (1). The function of this is to prevent the plate separating spring (5) from rotating. As soon as the pressurised oil in the clutch stops, this separates the steel plates that lock the friction plate (3). 19.

20.

Install the steel plates, separating rings and friction disks, in the order shown in the fig. 13

MOIL13TR00229AA

MOIL13TR00225AA

Press down the end plate (1) and use appropriately sized seeger pliers to install the seeger (2), then release the end plate.

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Transmission - Semi-Powershift transmission internal components

21.

22.

Rotate the 180 Â° C3/C4 clutch housing .Install on the support shaft (4) the C4 clutch support shaft roller bearing (3), the steel thrust washer (2) and the C4 clutch driven gear front roller bearing (1).

MOIL13TR00218AA

MOIL13TR00224AA

Install the hub (2) in the C4 clutch housing (3), on the support shaft (4).

NOTE: Make sure that the previously mounted lubrication oil seal (1) is correctly in its seat.

23.

Assemble the C4 clutch steel plates, friction plates and the end plate as shown below.

MOIL13TR00231FA

C4 clutch pressure plate ring, hub, friction plates and steel plates - exploded view 47538922 29/05/2013

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Transmission - Semi-Powershift transmission internal components

1 3 5 7 9

Friction plates x 10 End plate Steel plates x 10 Lubricating oil gasket Steel washer

2 Snap ring 4 Separating springs x 10 6 Separating spring anti-rotation pin 8 Clutch hub 10 C3/C4 clutch housing

NOTE: To assemble the separating springs use the precautions described for the C3 clutch. 24.

25.

26.

Using suitable snap ring pliers, install the snap ring (1).

MOIL13TR00217AA

MOIL13TR00216AA

MOIL13TR00215AA

Install the C4 clutch driven gear rear roller bearing (2) and the C4 driven gear (1).

Install the polyamide thrust washer (3). Install the manifold (2). Install the washers (1), the four retaining bolts.

NOTE: Check that the clutch assembly can freely rotate on the support shaft with no interference, and that there is sufficient axial clearance for the C4 clutch driven gear.

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00165GA

Output shaft and high/low gear range synchroniser - exploded view 1 3 5 7 9

Driven gear for slow speed gears `D' shaped steel washer Snap ring Driven shaft Polyamide thrust washer

2 Needle bearing 4 Snap ring 6 Hi/low gear range synchroniser 8 Needle bearing 10 Two cluster gears

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00166FA

Hi/low gear range synchroniser 1 External engagement coupler/cone 3 Sliding engagement coupler 5 Friction cone 7 Spring 9 Poppet ball guide

2 Friction cone 4 Centre hub 6 External engagement coupler/cone 8 Detent ball

Next operation: Semi-Powershift transmission - Service instruction (21.111).

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Transmission - Semi-Powershift transmission internal components

Transmission internal controls - Travel adjust 1.

ADJUSTMENT OF FORWARD/REVERSE AND MAIN (1-4/5-8) SYNCHRONISERS To access the forks and the synchroniser control rods, remove the mat and the cab floor .Remove the transmission cover panel to access the shift rails (1) and control forks (2). The adjustment procedure is the same for both synchronisers.

MOIL13TR00043AA

MOIL13TR00044AA

MOIL13TR00045AA

Remove the detent spring, plunger and ball from the transmission cover.

Insert the special tool 380002598 (1) in the small piston seat and place the tip (2) of the special tool in the hole of the 2 mm control rod, half way between the forward and reverse detent positions. this way the control rod will find its position and lock into the neutral position.

Remove the two locking screws that fix the selector fork to the control rod.

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Transmission - Semi-Powershift transmission internal components

Using a suitable lever, place the synchroniser completely in the engagement position and measure the dimension (A).

MOIL13TR00046AA

MOIL13TR00047AA

MOIL13TR00048AA

Now place the synchroniser in the opposite complete engagement position and measure the dimension (B). Replace the detent spring, plunger and ball. Set the shift rail to neutral. Adjust the fork to its neutral position. Neutral N = (A + B)/2 Tighten the fork lock screws.

HIGH/LOW GEAR RANGE GROOVE ADJUSTMENT 7.

Place the high/low gear range synchroniser in the neutral position .Loosen the tightening screw (1). Position the high/low selector lever in the cab centrally. Tighten the tightening screw (1). Engage the high/low selector lever and make sure that the synchroniser engages fully. If the lever interferes with the sector on the console, repeat the adjustment procedure.

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Transmission - Semi-Powershift transmission internal components

Gears - Remove - Central section removal. Prior operation: Clutch Range clutch - Remove (21.152).

MOIL13TR00167FA

1 C2 clutch driven gear (37 teeth) 3 Forward gear (37 teeth) 5 Main range synchroniser support shaft 7 Lower shaft 9 Inner cover plate 1.

2 Reverse gear (33 teeth) 4 Main rang (1-4/5-8) synchroniser 6 Low gear range main gear (53 teeth) 8 Lower shaft

Remove the inner cover plate retaining bolts.

MOIL13TR00188AA

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Transmission - Semi-Powershift transmission internal components

Install two of the retaining bolts into the separating holes.

MOIL13TR00189AA

MOIL13TR00190AA

MOIL13TR00191AA

MOIL13TR00193AA

NOTE: Do not torque the bolt at this time. 3.

Rotate the transmission to a horizontal position. While tightening the screws previously places in the separating holds, use an appropriate lever (1) to detach the forward/reverse synchroniser from the forward gear.

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

Remove the inner cover assembly (1) from the transmission housing. 5.

Rotate the transmission to a vertical position. Using suitable snap ring pliers, expand the snap ring (1) and remove the synchroniser and main low gear assembly.

NOTE: Use a suitable lever to release the main low gear assembly while expanding the snap ring.

Next operation: Gears - Disassemble (21.152). 47538922 29/05/2013

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Transmission - Semi-Powershift transmission internal components

Gears - Assemble - Central section assembly. Prior operation: Gears - Disassemble (21.152). 1.

Install the support shaft if necessary. Install the steel thrust washer (1), the roller bearing (2), the reverse idler gear (3) and the steel thrust washer (1).

NOTE: For the time being do not install the snap ring (5).

MOIL13TR00178AA

MOIL13TR00176AA

MOIL13TR00179AA

MOIL13TR00186AA

Install the inner cover plate (1).

NOTE: Support the lower shaft, the synchroniser assembly and the reverse idler gear.

Install the forward/reverse synchroniser end play shims (1).

Using suitable snap ring pliers, install the front bearing retaining snap ring (1)

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Transmission - Semi-Powershift transmission internal components

Assembly the bearing retaining plate and tighten the (1) retaining bolts.

MOIL13TR00187AA

MOIL13TR00049AA

Using suitable snap ring pliers, install the reverse idler gear snap ring (1).

Next operation: Gears - Clearance (21.152).

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Transmission - Semi-Powershift transmission internal components

Gears - Disassemble Center Section Prior operation: Gears - Remove (21.152).

MOIL13TR00167FA

Drive Line Components 1 C2 clutch driven gear 3 Forward gear (37 teeth) 5 Main range synchroniser support shaft 7 Lower shaft 9 Inner cover plate

2 Reverse gear (33 teeth) 4 Main range (1-4/5-8) synchroniser 6 Low gear range main gear (53 teeth) 8 Forward/reverse synchroniser

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00168FA

Cross Sectional View 1 Support shaft 3 Roller bearing 5 Forward/reverse synchroniser 7 Main range (1-4/5-8) synchroniser 9 Roller bearing 11 Needle bearing 13 Low gear range main gear (53 teeth) 15 Main range (1-4/5-8) synchroniser retaining snap ring 17 Needle bearing 19 Thrust washer

2 Snap ring 4 Reverse gear (33 teeth) 6 Forward/reverse synchroniser retaining snap ring 8 Needle bearing 10 Needle bearing 12 Snap ring 14 Needle bearing 16 Thrust washer 18 Needle bearing

Middle Section Disassembly 1.

Using suitable snap ring pliers, remove the reverse idler gear snap ring (1).

MOIL13TR00049AA

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Transmission - Semi-Powershift transmission internal components

Remove the front bearing retaining plate.

MOIL13TR00175AA

MOIL13TR00176AA

MOIL13TR00179AA

MOIL13TR00176AA

Using suitable snap ring pliers, remove the front bearing retaining snap ring (1).

Remove the forward/reverse synchroniser end float adjustment shims (1).

Remove the inner cover plate (1).

NOTE: Support the lower shaft, synchroniser assembly and the reverse idler gear.

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Transmission - Semi-Powershift transmission internal components

Remove the steel thrust washer (4), reverse idler gear (3), needle roller bearing (2) and the steel thrust washer (1). Remove the support shaft if necessary.

MOIL13TR00178AA

MOIL13TR00181AA

Removing the forward/reverse synchroniser and related parts

Remove the needle roller bearing (1), forward gear (2), snap ring (5), needle roller bearing (3) and the synchroniser gears (4).

MOIL13TR00180AA

MOIL13TR00177AA

Using suitable snap ring pliers, remove the forward/ reverse synchroniser retaining snap ring (1).

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Transmission - Semi-Powershift transmission internal components

10.

Remove the forward/reverse synchroniser (1).

MOIL13TR00182AA

MOIL13TR00183AA

Remove the reverse gear (1), needle roller bearing (2), 'D' shaped washer (3) and the snap ring (4). Using a suitable hydraulic press, remove the roller bearing (5) from the forward/reverse synchroniser support shaft (6).

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00166FA

Forward/Reverse synchroniser Exploded View 2 Friction cone 4 Centre hub 6 External engagement coupler/cone 8 Detent ball

1 External engagement coupler/cone 3 Sliding engagement coupler 5 Friction cone 7 Spring 9 Poppet ball guide

Assembling the forward/reverse synchroniser and related parts 11.

Using a suitable hydraulic press, install the roller bearing (5) onto the forward/reverse synchroniser support shaft (6). Install the snap ring (4), 'D' shaped washer (3), needle roller bearing (2), and the reverse gear (1).

MOIL13TR00183AA

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Transmission - Semi-Powershift transmission internal components

12.

13.

Install the forward/reverse synchroniser (1).

MOIL13TR00182AA

MOIL13TR00177AA

Using suitable snap ring pliers, install the forward/ reverse synchroniser retaining snap ring (1).

14. NOTICE: When assembling the synchroniser assemblies, it is essential that the forward gear is installed correctly. 15.

16.

1. Forward/reverse synchroniser side 2. 1-4/5-8 synchroniser side

MOIL13TR00184AA

MOIL13TR00180AA

Install the synchroniser gears (4), needle roller bearing (3), snap ring (5), forward gear (2), and the needle roller bearing (1).

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Transmission - Semi-Powershift transmission internal components

Removal/assembly of the main range (1-4/5-8) synchroniser and related parts

17.

MOIL13TR00185AA

MOIL13TR00177AA

Remove the outer cone/coupling and friction cone from the main range (1-4/5-8) synchroniser. Using suitable snap ring pliers, remove the main range (1-4/ 5-8) synchroniser retaining snap ring (1).

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00169FA

Main Range (1-4/5-8) Synchroniser And Related Parts 1 Roller bearing 3 Roller bearing retaining snap ring 5 Low gear range main gear (53 teeth) 7 Snap ring 9 Washer

2 Snap ring 4 Needle bearing 6 Main range (1-4/5-8) synchroniser 8 Needle bearing 10 Main range (1-4/5-8) synchroniser support shaft

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Transmission - Semi-Powershift transmission internal components

MOIL13TR00166FA

Main Range (1-4/5-8) Synchroniser 1 External engagement coupler/cone 3 Sliding engagement coupler 5 Friction cone 7 Spring 9 Poppet ball guide

2 Friction cone 4 Centre hub 6 External engagement coupler/cone 8 Detent ball

18.

Using suitable snap ring pliers, install the main range (1-4/5-8) synchroniser retaining snap ring (1).

19.

Install the outer cone/coupling and friction cone to the main range (1-4/5-8) synchroniser.

MOIL13TR00177AA

Next operation: Gears - Visual inspection (21.152).

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Transmission - Semi-Powershift transmission internal components

Gears - Clearance Prior operation: Gears - Disassemble (21.152) Gears - Visual inspection (21.152). NOTE: Adjust the play of the components on the forward/reverse synchroniser support shaft. The clearance is obtained by placing shims behind the forward/reverse synchroniser support shaft bearing retaining snap ring. NOTICE: This must be done with the transmission in the vertical position, with the components on the rear installed and with the rear upper shaft rear bearing retainer installed and firmly fixed in position. 1.

Remove the forward/reverse synchroniser bearing retaining plate.

MOIL13TR00175AA

MOIL13TR00186AA

MOIL13TR00179AA

Using suitable snap ring pliers, remove the forward/ reverse synchroniser retaining snap ring (1).

Remove the forward/reverse synchroniser end play shims (1).

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Transmission - Semi-Powershift transmission internal components

Using suitable snap ring pliers, install the forward/ reverse synchroniser retaining snap ring (1).

MOIL13TR00186AA

MOIL13TR00187AA

MOIL13TR00194AA

MOIL13TR00195AA

Install the forward/reverse synchroniser bearing retainer plate and tighten the retaining (1) bolts.

NOTE: Using a suitable soft mallet, lightly bang the synchroniser upper shaft to position the components. Be careful not to damage any components.

Using a suitable dial gauge, measure the end play of the forward/reverse synchroniser.

For this operation, lift the forward/reverse synchroniser on the positions indicated. This measurement is identified with H1. To calculate the end play shims for the forward/reverse synchroniser (S) proceed as follows: S = H1 - 0.5 mm Where: H1 = End-float of the forward/reverse synchroniser 0.5 mm = Average of the required end play, with a tolerance of 0.4 to 0.6 mm S = Forward/reverse synchroniser end play shims.

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Transmission - Semi-Powershift transmission internal components

Install the calculated adjustment shims. Tighten the retaining bolts (1).

NOTE: The range of shims available is from: 0.50 mm (0.0197 in) รท 2.30 mm (0.0906 in) with increments of 0.10 mm (0.0039 in) .

MOIL13TR00187AA

MOIL13TR00196AA

Install the roller bearing (2) and the steel thrust washer (1) .

Next operation: Gears - Assemble (21.152).

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Transmission - Semi-Powershift transmission internal components

Gears - Visual inspection Prior operation: Gears - Disassemble (21.152). 1.

Check the main range synchroniser and forward/reverse synchroniser components for wear or damage, proceeding as follows:Check the cone (1) for wear, damage or excessive discolouration; in this case, replace the synchroniser. Check the clearance between the cone and the end plate (2), if less than required replace the synchroniser.

MOIL13TR00192AA

Measuring the working conditions of the main range synchroniser 1 Friction cone 3 Feeler gauge

Main range synchroniser 1-4, 5-8 Forward/reverse synchroniser Hi/low gear range synchroniser

2 Cone/external coupling

Minimum clearance mm 0,5 0,8 0,85

Next operation: Gears - Clearance (21.152) Gears - Assemble (21.152).

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Inches 0.020 0.0315 0.0335

Index Transmission - 21 Semi-Powershift transmission internal components - 152 Clutch - Assemble - C1/C2 Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Clutch - Assemble - C3/C4 Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Clutch - Disassemble - Front section disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Clutch - Disassemble - Rear section disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Clutch - Remove - Front section removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Clutch - Remove - Rear section disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Clutch - Remove C3/C4 clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Clutch - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Clutch - Visual inspection C3/C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Gears - Assemble - Central section assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Gears - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Gears - Disassemble Center Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Gears - Remove - Central section removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Gears - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Transmission internal controls - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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Transmission - 21 Transmission/Rear drive - 118

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Transmission - 21 Transmission/Rear drive - 118

FUNCTIONAL DATA Transmission/Rear drive Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Transmission - Transmission/Rear drive

Transmission/Rear drive - Sectional view

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Transmission - Transmission/Rear drive

MOIL13TR00867JA

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Transmission - Transmission/Rear drive

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Transmission - Transmission/Rear drive

1 2 3 4

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 57 58 59 60 61 62 63 64 65 66 67 68 69

Screw securing transmission casing to gearbox. Torque 153 - 187 N·m (1354 - 1655 lb in) Rear transmission casing. PTO clutch drive shaft Bevel pinion bearing preload adjuster nut Tightening torque 467 - 515 N·m (4133 - 4558 lb in) Circlip PTO drive shaft bearing Circlip PTO driving gear PTO driven gear Circlip PTO driving shaft PTO drive shaft bearing Circlip PTO selection sliding sleeve Four-wheel drive driven gear PTO driven shaft Bevel crown wheel Rear pinion bearing Four-wheel drive engagement hydraulic fitting Transfer box lower cover retaining screw Tightening torque 43 - 53 N·m (381 - 469 lb in) Rear bearing for four-wheel drive shaft Rear bearing spacer Transfer box internal cover retaining screw Tightening torque 43 - 53 N·m (381 - 469 lb in) Inner cover of four-wheel drive transfer box Four-wheel drive driven gear Four-wheel drive front dog clutch gear Four-wheel drive engagement spring Spring retainer bottom Safety fifth wheel Thrust plate retaining screw Tightening torque 25 - 28 N·m (221 - 248 lb in) Differential support retaining screw Tightening torque 53 - 63 N·m (469 - 558 lb in) RH differential support Brake disc Brake drive piston Sealing Sealing Oil Drain Plug Differential unit Differential engagement front gear Transfer box lower cover retaining screw Tightening torque 43 - 53 N·m (381 - 469 lb in) Spring retaining plate

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Circlip

30 31 32

Front spring spacer Circlip securing four-wheel drive shaft bearing Four-wheel drive transfer box lower cover

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Four-wheel drive input shaft Circlip Front shaft bearing Circlip Oil seal retaining circlip Grooved bushing Oil seal Front pinion bearing Pinion bearing pre-load adjustment spacer Spacer Grooved bushing Circlip Circlip Circlip Circlip PTO shaft splined coupling sleeve

49 50 51

PTO shaft bearing Differential lock engaged indicator switch Swing bearing

52 53 54 55 56 70 71

Push rod return spring Push rod Differential lock status indicator rod Lock disengagement spring Differential bearing pre-load ring nut

LH differential support

73 74 75 76 77 78 79 80 81

Sealing Differential engagement front gear Sealing Differential lock engagement cylinder cap Needle thrust Circlip Sealing Circlip Sealing

Differential lock engagement piston

Crown wheel -pinion backlash adjustment shims

Transmission - Transmission/Rear drive

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Index Transmission - 21 Transmission/Rear drive - 118 Transmission/Rear drive - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47538922 29/05/2013 EN

SERVICE MANUAL Four-Wheel Drive (4WD) system

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Four-Wheel Drive (4WD) system - 23

[23.202] Electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

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Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202

FUNCTIONAL DATA Front-Wheel Drive (FWD) clutch Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Front-Wheel Drive (FWD) clutch Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dog clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Dog clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Internal line Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

DIAGNOSTIC Electro-hydraulic control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) clutch - Exploded view

MOIL13TR00864FA

Four-wheel drive dog clutch 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Shaft Sealing Driven gear with dog clutch teeth Control piston with dog clutch teeth Grooved washer Rear bearing Pipe union Sealing Sealing Pipe union retaining pin Sealing Driven gear oil grub screw Seal and anti-extrusion ring Seal and anti-extrusion ring Seal

15 16 17

Engagement sleeve Engagement spring Spring retaining plate

18 19 20 21 22 23 24 25 26 27

Circlip Spacer Bearing Locking ring Gear Locking ring Bearing Seal Oil seal Locking ring

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) clutch - Sectional view

MOIL13TR00865FA

KEY TO FOUR-WHEEL DRIVE TRANSFER BOX 1 Oil seal 2 Circlip 3 Brake discs 4 Front pinion bearing 5 Brake disc hub 6 Seal and anti-extrusion ring 7 Driven gear for ground speed power take-off 8 Four-wheel drive driving gear 9 Rear pinion bearing 10 Four-wheel drive front dog clutch gear 11 Four-wheel drive driven gear 12 Bevel crown wheel 13 Seal 14 Union 15 Retaining bolt for lower cover of four-wheel drive transfer boxTorque 43/53 N·m (380.6/469.1 lb in) 16 Seal 17 Pipe union retaining pin 18 Seal 19 Seal

20 Inner cover of four-wheel drive transfer box Torque 43/53 N·m (380.6/469.1 lb in) 21 Rear bearing for four-wheel drive shaft 22 Rear bearing spacer 23 Oil Drain Plug 24 Four-wheel drive engagement spring 25 Seal and anti-extrusion ring 26 Spring retaining plate 27 Circlip 28 Front spring spacer 29 Four-wheel drive shaft middle bearing 30 Four-wheel drive transfer box lower cover 31 Circlip 32 Four-wheel drive shaft 33 Circlip 34 Seal

35 Front bearing for four-wheel drive shaft 36 Seal 37 Oil seal carrier 38 Splined bushing

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) clutch - Dynamic description

MOIL13TR00934GA

1 3 5

Spring retaining plate Front dog clutch gear Driving gear

Four-wheel drive dog clutch (engaged) 2 Spring 4 Driven Gear

Key to colours in figure B Return to reservoir

The for-wheel drive solenoid valve is de-energised and spring (2) pushes against front dog clutch gear (3) which meshes with driven gear (4). Drive is transmitted from the driving gear (5), mounted on the rear transmission pinion, to the driven gear (4) and from there, via the front gear (3) fixed to the drive shaft, to the front axle.

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

MOIL13TR00935GA

1 3 5

Spring retaining plate Front dog clutch gear Driving gear

Four-wheel drive dog clutch (disengaged) 2 Spring 4 Driven Gear

Key to colours in figure B Low pressure circuit

The solenoid valve of the four-wheel drive clutch is de-energised thereby allowing the oil flow from the low pressure circuit to apply pressure on the surface of the dog clutch gear (3), which compresses the spring and disengages from the driven gear (4). Consequently, the driven gear (4) can rotate freely and drive is not transmitted to the drive shaft.

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) clutch - Remove Prior operation: Drive shaft - Remove (23.314)

WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Lift the steps using the lever (1), open the battery compartment using the lever (2) and disconnect the negative battery cable.

MOIL12TR00670AA

MOIL13TR00197AA

MOIL13TR00444AA

Remove the drain plug (1) and drain the oil into a suitable container. Replace the plug after draining the oil.

Remove the oil supply tube retaining bolt (1).

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Remove the rear transmission lower cover axle.

MOIL13TR00205AA

MOIL13TR00206AA

MOIL13TR00445AA

MOIL13TR00446AA

Remove the four-wheel drive clutch inner cover.

Using suitable circlip pliers, remove the circlip (1) securing the oil seal carrier of the four-wheel drive shaft.

Using a suitable lever, remove the drive coupling (1) and the carrier of the four-wheel drive shaft oil seal.

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Using suitable circlip pliers, remove the bearing retaining circlip (1).

MOIL13TR00447AA

MOIL13TR00448AA

Using the shop made slide hammer puller (1), remove the four-wheel drive shaft (2). Remove the four-wheel drive clutch assembly from the underneath the rear transmission.

NOTE: Using a suitable hydraulic jack, support the fourwheel drive engagement assembly. The four-wheel drive shaft cannot be removed completely from the rear axle housing. To remove the drive shaft from the rear axle housing, separate the gearbox from the rear transmission.

Next operation: Front-Wheel Drive (FWD) clutch - Disassemble (23.202)

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) clutch Dog clutch - Disassemble Prior operation: Removal of the clutch - see Front-Wheel Drive (FWD) clutch - Remove (23.202) . 1.

. Remove grooved washer (3) , four-wheel drive driven gear (2) and spacer (1).

MOIL13TR00861AA

MOIL13TR00862AA

Use a puller and a metal washer of suitable thickness to avoid damaging the surface (1) on which the puller bears. Compress the spring pack and remove the circlip (2)

Next operation: Front-Wheel Drive (FWD) clutch - Assemble (23.202)

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) clutch Dog clutch - Assemble Prior operation: Front-Wheel Drive (FWD) clutch - Disassemble (23.202) 1.

Replace the seals if necessary.

NOTE: Apply the specified transmission oil to the seals. 2.

Use a puller and a metal washer of suitable thickness to protect the surface (1) on which the puller bears. Compress the spring pack and remove the circlip (2).

MOIL13TR00862AA

MOIL13TR00861AA

Remove grooved washer (3) , four-wheel drive driven gear (2) and spacer (1).

Next operation: Installation of the clutch, - see Front-Wheel Drive (FWD) clutch - Install (23.202) .

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) clutch - Install Prior operation: Front-Wheel Drive (FWD) clutch - Exploded view (23.202) Front-Wheel Drive (FWD) clutch - Assemble (23.202)

Install a new O-ring (1) on the drive shaft.

MOIL13TR00739AA

MOIL13TR00740AA

MOIL13TR00741AA

Install new O-rings (1) and new ring seals (2) on the drive shaft. Apply transmission oil of the specified type to the O-rings and the ring seals.

Install the four-wheel drive clutch assembly in the rear transmission casing. Install the drive shaft (1).

NOTE: Using a suitable hydraulic jack, support the fourwheel drive engagement assembly.

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Using suitable circlip pliers, install the bearing retaining circlip (1).

MOIL13TR00447AA

MOIL13TR00742AA

MOIL13TR00743AA

MOIL13TR00744AA

Install a new O-ring (1) on the oil seal carrier.

Install a new oil seal (2)in the relative carrier (1).

Install the four-wheel drive coupling (1), the oil seal carrier (2) and the relative circlip (3).

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Install the inner cover of the four-wheel drive clutch. Tighten the retaining bolts (1) to a torque of 48 N·m (425 lb in).

NOTE: Apply LOCTITE® 243 to the threads of the retaining bolts.

10.

11.

MOIL13TR00745AA

MOIL13TR00746AA

Clean and carefully degrease the mating surfaces and apply a bead of sealant of approx. 2 mm (0.1 in) in diameter, following the pattern shown in the figure.

Install the lower cover of the rear axle. Tighten the retaining bolts (1) to a torque of 48 N·m (425 lb in).

MOIL13TR00747AA

MOIL13TR00444AA

Install the oil supply tube retaining bolt (1).

Next operation: Drive shaft - Install (23.314) . Top up the transmission with oil of the correct specification - refer to Consumables Lubrications and Coolants. . 47538922 29/05/2013

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Internal line - Remove Prior operation: Removal of the four-wheel drive clutch - see Front-Wheel Drive (FWD) clutch - Remove (23.202). 1.

Remove O-ring (2) and oil delivery sleeve retaining pin (1)

MOIL13TR00748AA

MOIL13TR00863AA

Using a suitable internal puller, remove oil delivery sleeve (1) and bearing (2).

Next operation: Internal line - Install (23.202)

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Internal line - Install Prior operation: Internal line - Remove (23.202) 1.

Install new O-rings (1) on the oil delivery manifold.

MOIL13TR00773AA

MOIL13TR00774AA

MOIL13TR00748AA

Install the oil delivery manifold (2) and the bearing (1) in the rear transmission casing.

Install retaining pin (1) of the oil delivery manifold and a new O-ring (2).

Next operation: Installation of the 4WD clutch - refer to Front-Wheel Drive (FWD) clutch - Install (23.202).

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Electro-hydraulic control - Troubleshooting NOTE: If the front wheel drive does not function correctly, first check whether any error codes have been logged by the controllers. These are defined by the error code range of 6001 to 7000 - see Electronic module - View (55.640). To retrieve error codes and view the relative fault diagnosis charts, see Electronic module - HB - Display stored fault codes (55.640). Problem 4WD does not engage.

Possible Cause Correction Four wheel drive engagement switch faulty. Replace the four wheel drive engagement switch. Four wheel drive control solenoid valve Repair or replace solenoid valve. stuck open. Worn-out clutch discs. Replace clutch plates. 4WD does not engage. Four wheel drive engagement switch faulty. Replace the four wheel drive engagement switch. Four wheel drive control solenoid valve Repair or replace solenoid valve. stuck open. Worn-out clutch discs. Replace clutch plates. Four wheel drive does not Low transmission oil. Refill to the correct oil level. disengage Faulty low pressure circuit. Test the pressure in the low pressure circuit. Faulty four wheel drive engagement circuit. Inspect circuit. Four wheel drive control solenoid valve Repair or replace the solenoid valve. stuck closed. Oil leaks through the oil seals with con- Replace oil seals. sequent pressure drop: hub, piston, and transfer box shaft oil seals.

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Index Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202 Electro-hydraulic control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Front-Wheel Drive (FWD) clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front-Wheel Drive (FWD) clutch - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front-Wheel Drive (FWD) clutch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Front-Wheel Drive (FWD) clutch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Front-Wheel Drive (FWD) clutch - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Front-Wheel Drive (FWD) clutch Dog clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Front-Wheel Drive (FWD) clutch Dog clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Internal line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Internal line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Four-Wheel Drive (4WD) system - 23 Drive shaft - 314

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Four-Wheel Drive (4WD) system - 23 Drive shaft - 314

TECHNICAL DATA Drive shaft General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Drive shaft Remove (Standard axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install (Standard axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - General specification 1 mm; 1.2 mm; 1.5 mm; 1.8 mm; 2 mm; 2.2 mm; 2.5 mm; 3 mm; 3.3 mm; 3.7 mm; 4 mm; 4.3 mm 1.2 - 1.7 mm (0.047 - 0.067 in)

Front Sleeve Positioning Adjust Ring Shims Front Sleeve End-Play

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Remove (Standard axle) WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Lift the steps using the lever (1), open the battery compartment using the lever (2) and disconnect the negative battery cable

MOIL12TR00670AA

MOIL13TR00775AA

MOIL13TR00388AA

Remove the four-wheel drive shaft guard (1).

Open out the cicirlip (1) and slide it (1) with the sleeve (2) along the four-wheel drive shaft.

NOTE: After disconnecting the shaft from the front axle shaft, recover the sleeve adjustment shim

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Four-Wheel Drive (4WD) system - Drive shaft

Remove the four wheel drive shaft and the central support.

MOIL13TR00200AA

Next operation: Drive shaft - Install (23.314) (Standard axle)

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Install (Standard axle) Prior operation: Drive shaft - Remove (23.314) (Standard axle)

Install the four wheel drive shaft and the central support.

MOIL13TR00200AA

MOIL13TR00199AA

MOIL13TR00775AA

Open out the cicirlip (1) and slide it (1) with the sleeve (2) along the four-wheel drive shaft.

NOTE: With the shaft installed, use a feeler gauge to measure the end float of the sleeve on the shaft. This should be 1.2 mm (0.05 in) to 1.7 mm (0.07 in) , if not, adjust the shim thickness.

Install the four-wheel drive shaft guard (1).

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Four-Wheel Drive (4WD) system - Drive shaft

Reconnect the negative battery cable, close the battery cover using lever (2) and lower the steps, securing them with lever (1).

MOIL12TR00670AA

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Index Four-Wheel Drive (4WD) system - 23 Drive shaft - 314 Drive shaft - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Drive shaft - Install (Standard axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Drive shaft - Remove (Standard axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47538922 29/05/2013 EN

SERVICE MANUAL Front axle system

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Front axle system - 25

[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

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Front axle system - 25 Powered front axle - 100

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Front axle system - 25 Powered front axle - 100

TECHNICAL DATA Powered front axle Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Powered front axle Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Axle support Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SERVICE Four-Wheel Drive (4WD) axle Remove 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install 4 WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Assemble 4 WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Front axle system - Powered front axle

Powered front axle - Torque

WLAPL4S25C101H

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Front axle system - Powered front axle

MOIL13TR01296HA

Front axle torque settings Thread size

PARTS TO BE TIGHTENED Front axle support retaining bolt ( (C1), 1)

M18 X 1.5

Rear axle support retaining bolt ( (C2) , 1)

M18 X 1.5

Steering cylinder head locking ring nut ( (C3) , 1)

M22 X 1.5

Steering knuckle fixing on the piston ( (C4) , 1)

M22 X 1.5

Nut retaining steering ball joint on the stub axle ( (C5) , 1) M20 X 1.5

Steering cylinder retaining screws ( (C6) , 1 )

M18 X 1.5

Locking piston seat retaining bolt ( (C7) , 2)

M10 X 1.25

Differential housing support casing retaining bolt ( (C8) , 2) M14X1 Bevel crown wheel to differential support retaining bolt ( (C9) , 2)

M12 X 1

Brake pipe bracket retaining bolt ( (C10) , 2)

M12 X 1.25

Axle shaft bearing bushes retaining bolt ( (C11) , 2)*

M12 X 1.25

Final drive bearing retaining thrust washer retaining bolts ( M12 X 1.25 (C12), 2) Final drive ring gear support retaining bolts, axle version with brakes ( (C13), 2) Ring nut locking hub on stub axle, axle version without brakes ( (C14) , 2)

M10 X 1.25 M72X2

Final drive to hub retaining bolt ( (C15) , 2)

M10 X 1.25

Stub axle pin retaining bolt ( (C16) , 2)

M10 X 1.25

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Tightening torque Kgm Nm (lbft) 350 - 410 N·m (258.15 - 302.40 lb 35.5 to 41.6 ft) 350 - 410 N·m (258.15 - 302.40 lb 35.5 to 41.6 ft) 185 - 206 N·m (136.45 - 151.94 lb 18.8 to 20.9 ft) 267 - 287 N·m (196.93 - 211.68 lb 27.1 to 29.1 ft) 124 - 149 N·m (91.46 - 109.90 lb 12.6 to 15.2 ft) 385 - 442 N·m (283.96 - 326.00 lb 36.5 to 45 ft) 45 - 50 N·m (33.19 4.6 to 5.1 - 36.88 lb ft) 130 - 144 N·m (95.88 - 106.21 lb 13.2 to 14.6 ft) 130 - 144 N·m (95.88 - 106.21 lb 13.2 to 14.6 ft) 75 - 90 N·m (55.32 7.6 to 9.1 - 66.38 lb ft) 45 - 55 N·m (33.19 4.5 to 5.6 - 40.57 lb ft) 90 - 100 N·m (66.38 - 73.76 9.1 to 10.1 lb ft) 75 - 82 N·m (55.32 7.6 to 8.4 - 60.48 lb ft) 394 N·m (290.60 40 lb ft) 55 - 67 N·m (40.57 5.6 to 6.8 - 49.42 lb ft) 55 - 67 N·m (40.57 5.6 to 6.8 - 49.42 lb ft)

Front axle system - Powered front axle

Thread size

PARTS TO BE TIGHTENED Ring gear positioning ring nuts retaining grub screw ( (C17) , 2 *

M12 X 1.25

Tightening torque Kgm Nm (lbft) 11 - 13.5 N·m (8.11 1.1 to 1.3 - 9.96 lb ft)

NOTE: * Apply LOCTITE® 243 on the thread.

Powered front axle - Special tools Indispensable tools 380000268: Front axle drive pinion nut spanner. 380000257: Front axle drive pinion retaining tool. 380000252: Front axle differential casing bearing ring nut spanner. 380000269: Wrench for front axle wheel hub bearing retaining nut. 380000270: Pair of grips for front axle hub bearing extraction. 380000265: Front axle pivot pin removal tool. 380000234: Front axle swivel pin bearing outer race puller. 380000235: Tool for measurement of rolling drag torque of front axle bearings. 380200017: Sunken seal key on hub (version without brakes). 380200018: Sunken seal key on spindle (version with brakes). 380200019: Sunken seal key on spindle for axle shafts. 380200041: Sunken seal key on pinion. 380200042: Dust seal key on pinion.

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Front axle system - Powered front axle

Tools that can be made in the workshop

WLAPL4S25C103H

Tool to be made for adjustment of pinion bearing pre-load

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Front axle system - Powered front axle

For the screw order P/N 15998934, for the nut order P/N 12164524 The remainder make of UNI C40 . (A) . - Machine the end of the hole to remove approximately 1 mm (0.0394 in) obtaining a level surface to facilitate measuring. (B) . - Machine a face of the nut to remove approximately 1 mm (0.0394 in) obtaining a level surface to facilitate measuring.

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Front axle system - Powered front axle

Tool to make for front axle wheel disassemblyâ&#x2C6;&#x2019;assembly

SEZ25CAP1F-1

Stamp number 50165 on the tool - Measurements in mm. Make using UNI C40 material.

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Front axle system - Powered front axle

Tool to make for removalâ&#x2C6;&#x2019;installation of the final drive cover

SEZ25CAP1F-2

Stamp number 50164 on the tool - Measurements in mm. Make using UNI C40 material.

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Front axle system - Powered front axle

Powered front axle - Static description All the models in the range have their front axle pivoted at the centre with the pivot and drive gear shaft coaxial to the tractorâ&#x20AC;&#x2122;s longitudinal axis; the drive gear shaft has no universal joints. The differential has two planet pinions; drive is transmitted to lateral epicyclic final drive units (installed on the wheel hubs) through universal joints which do not require any maintenance. For the hydraulically controlled front gear--type differential lock, see Differential lock - Static description (25.102) .

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Front axle system - Powered front axle

Axle support - Sectional view Approximate cross--sectional view for correctly fitting the axle support to the engine

SEZ25CAP1F-4

(1). Front axle support. (2). Crankcase front surface. (3). Engine sump front surface. (4). Shim. (5). Axle support to crankcase retaining bolt. (6). Sump to axle support retaining bolt. (7). Rear axle retaining bracket. (8). Differential support. (9). Steering cylinder.

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Remove 4WD NOTE: The front axle assembly can be removed from the tractor with either the propshaft removed from or installed in the tractor. The description below refers to removal of the front axle with the drive shaft installed on the tractor. For removal of the drive shaft refer to Front-Wheel Drive (FWD) - Disassemble (23.202) . 1.

Fold the steps upwards, after operating the retainer (1) . Turn the retainer (2) to remove the battery cover, then detach the negative cable.

WLAPL4S25C101A

WLAPL4S25C102A

PAG-296(1)82X52

Unscrew bolts (1) and remove the front mudguard supports (2).

Remove the split pins, lock pins and front ballast (1).

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Front axle system - Powered front axle

Take out the bolts (1) and remove the drive gear shaft guard (2).

Remove the circlip (2) and move the sleeve (1) in the direction indicated by the arrow until it is released from the groove on the drive.

Attach the front axle to a hoist using two nylon slings.

Raise the tractor and position a fixed stand under the engine sump.

WLAPL4S25C106A

SEZ25CAP1A-7

WLAPL4S25C108A

WLAPL4S25C109A

Unscrew the hoses of the power steering (1) from the fittings of the pipes (2) .

Remove the front differential lock fitting (1) and the hose (2) .

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Front axle system - Powered front axle

10.

11.

12.

Unscrew the retaining bolts and remove the front wheels.

SEZ25CAP1A-10

WLAPL4S25C111A

Take out the front axle rear support retaining bolts (1).

Take out the front axle front support retaining bolts (1).

WLAPL4S25C112A

13.

Using the hoist and the two nylon slings, one on each side, detach the front axle.

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Install 4 WD 1.

Position the axle, tighten the front and rear supports to the relative support.

Fit the front wheels.

Reconnect the differential lock pipe and the power steering pipes.

Using the hoist, raise the front part of the tractor.

Extract the fixed stand.

Remove the nylon slings from the axle.

Connect the drive shaft and position the guard.

Refit the two front mudguards.

Attach a nylon sling to the front ballasting, fit and secure in position with the lock rod.

10.

Reconnect the battery negative lead.

11.

Tighten to the prescribed torques (see the tightening torques chapter).

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Assemble 4 WD 1.

Refer to the illustrations on Four-Wheel Drive (4WD) axle - Sectional view (25.102), figures 1 and 2, for the positioning of the various parts.

Respect the tightening torques prescribed (see Powered front axle - Torque (25.100) ).

Carry out the adjustments described in Bevel gear set and differential carrier - Adjust (25.102) , Bevel gear set and differential carrier - Adjust Ring/Pinion Gears (25.102) , Steering knuckle and king pin - Adjust (25.108) .

Secure the ring nut, fit the seal, dust ring and propeller shaft sleeve thrust ring on the back of the bevel pinion.

NOTE: To mount the sunken oil seal use the tool 380200041, for the dust cup use tool 380200042. 5.

Mount the differential lock sleeve ( (60), Four-Wheel Drive (4WD) axle - Sectional view (25.102) figure 1) and the stop ring.

Mount the differential lock actuator unit together with the spring ( (50), Four-Wheel Drive (4WD) axle Sectional view (25.102) figure 1) and secure it with the 2 screws size 70 mm (2.76 in), tighten the other bolts then replace the two long ones with those of normal use.

Mount the rigid pipe for delivering oil to the differential lock (58) Four-Wheel Drive (4WD) axle - Sectional view (25.102) figure 1.

Install the bevel drive--differential support to the front axle housing applying sealing compound of diameter approximately 2 mm (0.08 in) mount the differential lock outside pipe.

Fit the axle shaft and screw.

10.

Fit the stub axle, the adjustment shims, the upper and lower pivot pins.

11.

Fit the wheel hub, final drive crown wheel and ring nut and tighten to the prescribed torque whilst rotating the hub to settle the bearings.

12.

Fit the final drive cover.

13.

Fit the front and rear supports and the oil drainage plugs.

14.

Mount the steering cylinder, secure it with the relevant screws and tighten them.

15.

Then reposition the power steering pipes.

16.

Inset the steering head on the stub axles then insert the lower nut and secure it.

17.

Mount the hoses to the rigid pipes of the power steering, fill up with oil then secure the filler caps.

18.

Mount the differential lock system pipes.

19.

Fit the front mudguard supports.

20.

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Index Front axle system - 25 Powered front axle - 100 Axle support - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Four-Wheel Drive (4WD) axle - Assemble 4 WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Four-Wheel Drive (4WD) axle - Install 4 WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Four-Wheel Drive (4WD) axle - Remove 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Powered front axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Powered front axle - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Powered front axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Front axle system - 25 Front bevel gear set and differential - 102

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Front axle system - 25 Front bevel gear set and differential - 102

TECHNICAL DATA Differential General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Differential lock General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Limited slip differential General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Differential lock Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Limited slip differential Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Bevel gear set and differential carrier Adjust Ring/Pinion Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Differential Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Limited slip differential Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

DIAGNOSTIC Differential lock Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Front axle system - Front bevel gear set and differential

Differential - General specification Bevel drive -- differential Type Pinion-crown gear ratio: - all models Backlash between bevel drive teeth: - all models

steering, load bearing structure, pivoting at centre 13/36 = 1:2.77 0.15 - 0.20 mm (0.006 - 0.008 in)

2.50 mm (0.098 in) - 2.55 mm (0.100 in) - 2.60 mm (0.102 in) - 2.65 mm (0.104 in) - 2.70 mm (0.106 in) - 2.75 mm (0.108 in) - 2.80 mm (0.110 in) - 2.85 mm (0.112 in) - 2.90 mm (0.114 in) - 2.95 mm (0.116 in) - 3 mm (0.118 in) - 3.05 mm (0.120 in) - 3.10 mm (0.122 in) - 3.15 mm (0.124 in) - 3.20 mm (0.126 in) - 3.25 mm (0.128 in) - 3.30 mm (0.130 in) - 3.35 mm (0.132 in) - 3.40 mm (0.134 in) - 3.45 mm (0.136 in) - 3.50 mm (0.138 in) - 3.55 mm (0.140 in) - 3.60 mm (0.142 in) Thickness of bevel pinion bearing adjustment rings ( (61) , Four-Wheel Drive (4WD) axle - Sectional view - 3.65 mm (0.144 in) - 3.70 mm (0.146 in) - 3.75 mm (0.148 in) - 3.80 mm (0.150 in) - 3.85 mm (0.152 in) (25.102) figure 1) 3.90 mm (0.154 in) - 3.95 mm (0.156 in) - 4 mm (0.157 in) - 4.05 mm (0.159 in) - 4.10 mm (0.161 in) - 4.15 mm (0.163 in) - 4.20 mm (0.165 in) - 4.25 mm (0.167 in) - 4.30 mm (0.169 in) - 4.35 mm (0.171 in) - 4.40 mm (0.173 in) - 4.45 mm (0.175 in) - 4.50 mm (0.177 in) - 4.55 mm (0.179 in) - 4.60 mm (0.181 in) - 4.65 mm (0.183 in) - 4.70 mm (0.185 in) - 4.75 mm (0.187 in) 4.80 mm (0.189 in) 0.9 mm (0.035 in) - 1 mm (0.039 in) - 1.1 mm (0.043 in) Thickness of bevel crown wheel position adjustment - 1.2 mm (0.047 in) - 1.3 mm (0.051 in) - 1.4 mm (0.055 rings ( (83) , Four-Wheel Drive (4WD) axle - Sectional in) - 1.5 mm (0.059 in) - 1.6 mm (0.063 in) - 1.7 mm view (25.102) figure 1) (version with differential lock) (0.067 in) - 1.8 mm (0.071 in) - 1.9 mm (0.075 in) - 2 mm (0.079 in) Clearance ( gn ) between sides of sun and planet pinion 0.12 - 0.18 mm (0.0047 - 0.0071 in) teeth Endfloat ( ga ) of the sun gears such as to determine ( 0.2 - 0.3 mm (0.0079 - 0.0118 in) gn) 1.4 mm (0.055 in) - 1.5 mm (0.059 in) - 1.6 mm (0.063 Thickness of sun pinion thrust washers ( (73) , in) - 1.7 mm (0.067 in) - 1.8 mm (0.071 in) - 1.9 mm Four-Wheel Drive (4WD) axle - Sectional view (0.075 in) - 2 mm (0.079 in) (25.102) figure 1)

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Front axle system - Front bevel gear set and differential

Differential lock - General specification Type

With front gears By means of two front teeth gears, one integral with the right axle shaft the other integral with the differential cage Controlled by the control unit of the gearbox / lift Electro-hydraulic, it is switched on simultaneously with the rear one by means of a button located on the operator's right-hand side

Operation Control

Operation

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Front axle system - Front bevel gear set and differential

Limited slip differential - General specification LIM--SLIP self--locking differential Friction disc, keyed on side gear ( (94), Four-Wheel Drive (4WD) axle - Sectional view (25.102) ): - quantity - thickness - maximum wear Friction disc, keyed on side gear ( (93), Four-Wheel Drive (4WD) axle - Sectional view (25.102)): - quantity - thickness - maximum wear Metal disc, keyed on differential casing ( (86), Four-Wheel Drive (4WD) axle - Sectional view (25.102)): - quantity - thickness

2 2.8 mm (0.11 in) 0.10 mm (0.004 in)

8 1.6 mm (0.06 in) 0.15 mm (0.006 in)

10 1.5 mm (0.06 in)

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Front axle system - Front bevel gear set and differential

Differential lock - Static description Front differential lock In rest conditions the oil inside the annular chamber of the piston (1) is static and not pressurized as the relative solenoid valve is in the discharge position (not energized). In these conditions, the helical spring (2) keeps the teeth of the two coupling sleeves of the differential lock apart. A: Front differential lock disengaged B: Front differential lock engaged

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Front axle system - Front bevel gear set and differential

MOIL13TR01297HA

: Discharged oil : Pressurized oil 47538922 29/05/2013

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Front axle system - Front bevel gear set and differential

Limited slip differential - Sectional view LIM--SLIP self--locking differential.

WLAPL4S25C101F

(1). Metal disc keyed onto differential casing. (2). Friction disc keyed onto side gear. (3). Friction disc keyed onto side gear.

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Front axle system - Front bevel gear set and differential

Limited slip differential - Static description LIM--SLIP self locking differential operation The differential with limited--slip locking ( LIM-SLIP ), (see Four-Wheel Drive (4WD) axle - Sectional view (25.102), detail (F) and (G), Limited slip differential - Sectional view (25.102) ) is of the two planet gear--type, provided with two multi--disk clutch assemblies fitted between the side gears and the differential casing. This differential lock device is totally automatic, requires no manual operation and notably reduces (without completely eliminating) wheel slipping that may result from tractor grip loss. The difference in revolutions, between the sun gears and the differential casing when a wheel begins to slip as a result of grip loss, is impeded by clutch assemblies that are compressed by axial thrusts from the bevel drive torque transmitted to the sun gears by means of the teeth on the two planet gears. These torque values may be different, according to the nature of the ground and the route followed by the tractor, and may vary in intensity thereby proportionally determining the axial stress on the clutches, allowing the sun gears to mesh with the differential casing which, in turn, permits the axle to overcome the unevenness of the ground.

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Front axle system - Front bevel gear set and differential

Bevel gear set and differential carrier - Adjust Ring/Pinion Gears Adjusting the bevel pinion shaft bearing preload with shims ( (61) Four-Wheel Drive (4WD) axle - Sectional view (25.102) ) NOTE: Refer to (84), Four-Wheel Drive (4WD) axle - Sectional view (25.102) . 1.

Use the tool to be made in the workshop, of drawing Powered front axle - Special tools (25.100) . Mount the bush on the screw of this tool in the inner race of the pinion rear support bearing supporting, the spacer ( (68) , Four-Wheel Drive (4WD) axle Sectional view (25.102) ) and the race of the front support bearing with the relevant bush, as shown in the figure. Position the end of the two bushes inside the spacer so as to center the latter too. Screw the relevant nut on the end of the screw, keeping its machined part facing towards the end. Once all the surfaces inside the tool are in contact; using a depth caliper or a micrometer make the measurement (L) , between the end of the screw and the face beneath the nut, for a more exact measurement, make three measurements at 120 Â° then calculate the average.

WLAPL4S25C170A

WLAPL4S25C171A

WLAPL4S25C172A

Remove it all and reassemble the tool with the two bushes and related bearings, on the differential support, without the spacer as shown in the figure. Also in this case, screw on the nut keeping the machined part on the outside.

Using a wrench (1) and an appropriate bush (2) for the screw and another wrench to keep the nut stationary, tighten the nut ensuring the bearings settle. NOTE: During these operations certain that the bearings settle. Tighten the ring nut in successive stages, turning the pinion between each stage.

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Front axle system - Front bevel gear set and differential

Tighten the ring nut to reach a rolling torque 0.49 0.98 N·m (0.36 - 0.72 lb ft) (0.05 to 0.1 kgm), measured with the torque wrench (1) , without considering the break-out torque.

WLAPL4S25C173A

WLAPL4S25C174A

SEZ25CAP1A-74

WLAPL4S25C137A

Measure the distance (L1) from the end of the screw to the face of the bolt beneath, also in this case, for a more precise measurement, make three readings at 120 ° then calculate the average. The bearing preload adjustment shim S ( (61) , Four-Wheel Drive (4WD) axle - Sectional view (25.102) ) will be: S = ( (L) − (L1) + 0.05 mm (0.0020 in) )

With the wrench (1) and the relevant bush (2) , remove the tool.

Refit the pinion on the support complete with the bearings, spacer, thrust washer ( (65) , Four-Wheel Drive (4WD) axle - Sectional view (25.102) ) of the adjustment shim ( (61) , Four-Wheel Drive (4WD) axle - Sectional view (25.102)), keeping it still with the tool 380000257 (1) , then tighten the ring nut with the tool 380000268 (2) .

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Front axle system - Front bevel gear set and differential

Tighten the ring nut to a torque of 382.5 NÂˇm (282.12 lb ft) (39 Kgm) ensuring the bearings bed in. Then check again that the rolling torque is: A1 < = 0.49 NÂˇm (0.36 lb ft) (0.05 kgm) without considering the break-out torque. Select a thinner shim if the torque is greater otherwise select one with a greater thickness it is less

WLAPL4S25C173A

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Front axle system - Front bevel gear set and differential

Differential - Overhaul FRONT AXLE DIFFERENTIAL NOTE: This procedure is to be considered valid for planet gears with Z1 = 12 teeth and sun gears with Z2 = 20 teeth and modulus m = 4.1 NOTE: When overhauling the differential assembly it is necessary to adjust the backlash between the teeth of the planet pinions and the side gears. 1.

Thoroughly clean the components of the differential to remove any traces of oil that would otherwise prevent accurate backlash measurement.

Fit the two sun gears without thrust washers on the differential casing.

Fit the planet pinions complete with thrust washers and pins and screw down the pin retaining bolts by a few turns to hold the pins in place.

Position a dial gauge on the differential housing.

Move the left--hand side gear to bring it into full contact with the planet pinion and then push it up against the differential housing, reading the end float ( Gs ) on the micrometer.

Repeat the above operations to measure the end float on the right--hand side gear ( Gd ). - The side gear end float will be 0.25 mm (0.010 in). - Therefore the rings to be inserted in the differential housing are given by: - Ss = Gs - 0.25 mm (0.010 in) for the left--hand sun gear; - Sd = Gd - 0.25 mm (0.010 in) for the right--hand sun gear.

Install shims as near as possible to the calculated value and, using a dial gauge and following the previously described procedure, check that the end float of the left-- and right--hand sun gears is approximately 0.25 mm (0.010 in).

SEZ25CAP1A-42

SEZ25CAP1A-43

NOTE: With an endfloat of ga = 0.20 - 0.30 mm (0.0079 - 0.0118 in) a clearance will be obtained between the teeth of gn = 0.12 - 0.18 mm (0.0047 - 0.0071 in) .

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Front axle system - Front bevel gear set and differential

Limited slip differential - Overhaul Front axle differential with limited-slip unit

MOIL13TR01226FA

Front axle differential with LIM â&#x2C6;&#x2019; SLIP 1.

Remove the bevel drive--differential casing assembly from the front axle, attach to support (4), lock in a vice and proceed with disassembly operations as follows.

Take out the Allen screws (3) retaining the right (5) and left ring nuts.

Check that the right-- and left--hand caps (1) are marked so as not to interchange them during assembly.

Remove the right (5) and left--hand bearing adjustment ring nuts from the bevel crown wheel.

Take out the bolts (2) and caps (1) and separate the bevel crown wheel from the bevel pinion support.

If necessary, take out the retaining bolts ( (C9), Powered front axle - Torque (25.100) figure 2) and the bevel crown wheel.

Disassemble the LIM--SLIP self--locking differential lock as follows.

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Front axle system - Front bevel gear set and differential

Remove the retaining bolts (6) from the differential half-casing.

Remove the differential pin (9), complete with the planet gears (7) the shims (8) and the retaining pin (2) from the half--casing (4).

Remove the side gear (5), friction disk ( (11), 3), metal disks (10) and friction disks (12).

10.

Remove the side gear (1) the friction disc (11), the metal discs (10) and the friction discs (12) from the half-casing (3).

11.

Check the wear on the metal disks (10) and the friction disks ( (11) and (12), see table below), replacing parts that are near their wear limit.

12.

Proceed with self--locking differential assembly operations, carrying out the previously described operations in reverse order, apply LOCTITE® 270 to the threads on the screws (6) and tighten to a torque value of 50 N·m (442.54 lb in).

13.

Refit the crown wheel (if previously disassembled) on the half--casing (3), tightening the bolts ( (C9), Powered front axle - Torque (25.100) figure 2) to a torque of 113 N·m (1000.13 lb in).

14.

Check the rolling torque of the bevel pinion, as indicated in Bevel gear set and differential carrier Adjust Ring/Pinion Gears (25.102) .

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SEZ25CAP1B-1

SEZ25CAP1A-44

Front axle system - Front bevel gear set and differential

15.

Assemble the crown wheel, complete with LIM-SLIP self-locking differential lock, on the bevel drive support, remembering to fit the previously marked crown wheel bearing support caps in the correct order and assemble and adjust the crown wheel bearings as indicated in Bevel gear set and differential carrier Adjust (25.102) .

SEZ25CAP1A-44

Friction parts detail Self--locking differential friction disks ( LIM-SLIP) Item no. (10) (11) (12)

Quantity

Name Metal disk Friction disk Friction disk

10 2 8

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Thickness mm-in . 1.5 mm (0.06 in) 2.8 mm (0.11 in) 1.6 mm (0.06 in)

Maximum wear per disc mm-in . 0.10 mm (0.004 in) 0.15 mm (0.006 in)

Front axle system - Front bevel gear set and differential

Differential lock - Troubleshooting Problem Possible Cause The differential lock fails Transmission oil level low. to engage. Clogged oil filter. Hydraulic pump faulty. Faulty differential lock--unlock switch. Lack of power supply to the solenoid valve: connections loose or damaged, contactor faulty. Differential lock control solenoid valve jammed in discharge position. Oil leakage through the seals with consequent pressure drop: piston seals or delivery pipe seals. Differential lock fails to Differential lock solenoid valve jammed in disengage. delivery position. Differential lock release spring broken. Lack of power supply to the solenoid valve: connections loose or damaged, contactor faulty. Switch governed by the brake pedal, conWith differential lock engaged, the differential nected to the control unit, defective. lock does not disengage when brake pedals are pressed.

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Correction Top up oil. Replace filter. Overhaul or replace the pump. Replace switch. Check electrical connections and replace defective parts. Overhaul or replace solenoid valve. Replace damaged seals.

Overhaul or replace solenoid valve. Replace spring. Check electrical connections and replace defective parts. Change the switch or repair the electrical system.

Index Front axle system - 25 Front bevel gear set and differential - 102 Bevel gear set and differential carrier - Adjust Ring/Pinion Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Differential - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Differential - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Differential lock - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Differential lock - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Differential lock - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Limited slip differential - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Limited slip differential - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Limited slip differential - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Limited slip differential - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

TECHNICAL DATA Steering knuckle and king pin General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Planetary drive and hub General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Steering knuckle and king pin Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Planetary drive and hub Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Wheel hub Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - General specification Thickness of steering knuckle bearing adjuster plates

0.10 mm (0.0039 in) 0.15 mm (0.0059 in) 0.20 mm (0.0079 in) 0.25 mm (0.0098 in) 0.30 mm (0.0118 in)

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Front axle system - Final drive hub, steering knuckles, and shafts

Planetary drive and hub - General specification Epicyclic final drive Reduction Ratio: - all models Front axle brake disk thickness - all models

12 : (12 + 72) = 1 : 7 4.45 - 4.55 mm (0.175 - 0.179 in)

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Adjust Stub axle NOTE: Position the front axle on stand 380000251 and proceed as follows: 1.

Smear NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE GREASE on the outer races of the bearings and fit the upper cover, without the plates, but with tool 380000235 (1). Tighten the retaining bolts to 64 NÂˇm (566.45 lb in).

SEZ25CAP1A-69

NOTE: At some points on the upper pin the lubricator is no longer positioned vertically, but is horizontal, for access with the front mudguard support. Put a few washers under the tool as shims, temporarily inserting longer screws. 2.

Fit the lower cover without the adjustment plate and lubricate the three retaining bolts with engine oil.

Gradually tighten the lower cover bolts in sequence, while simultaneously rotating the casing to allow excess grease to escape.

Using a torque wrench and tool 380000235 (1), check that the torque required to rotate the casing is: 3.9 - 5.8 NÂˇm (34.52 - 51.33 lb in), without considering the peak starting torque. If not, adjust by way of the lower cover bolts.

Measure the gap (H) created between the lower cover and the casing adjacent to each of the three bolts.

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SEZ25CAP1A-70

SEZ25CAP1A-71

Front axle system - Final drive hub, steering knuckles, and shafts

Calculate the average of the three values measured. The total thickness of the adjustment plates to be fitted under the lower cover will be given by: (S) = (H) If necessary, round the value down to the next 0.05 mm (0.002 in).

SEZ25CAP1A-72

Partially unscrew the lower cover bolts, insert the selected shims and tighten the bolts to a torque of: 64 NÂˇm (566.45 lb in).

Check that the torque necessary to rotate the casing is 3.9 - 9.8 NÂˇm (34.52 - 86.74 lb in), without considering the initial peak torque.

If the torque value measured is greater than the specified value, increase the thickness of the shims, if it is less than the specified value, reduce the thickness of the shims.

10.

Fit the grease nipples in the upper and lower covers and grease the assembly.

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Front axle system - Final drive hub, steering knuckles, and shafts

Planetary drive and hub - Disassemble Front epicyclic final drive without brake NOTE: Front epicyclic final drive removal and installation can be carried out with the axle detached and positioned on the stand 380000251, or with the axle fitted on the tractor. If the operation is performed with the axle fitted on the tractor, a support stand must be positioned under the engine sump. 1.

Position the axle on stand 380000251.

SEZ25CAP1A-51

SEZ25CAP1A-52

SEZ25CAP1A-53

Remove the plug (1) and drain the oil from the epicyclic final drive.

Unscrew the cover retaining bolts (1) on the final drive, screw in two pins (2) and, using an extracting tool inserted in the oil drainage plug hole, detach the cover (1).

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Front axle system - Final drive hub, steering knuckles, and shafts

Remove the notching (1) on the ring nut (2) retaining the wheel hub bearings.

SEZ25CAP1A-54

SEZ25CAP1A-55

SEZ25CAP1A-56

Remove the lock nut on the wheel hub bearings using wrench 380000269 (1).

Remove the wheel hub (1) together with the epicyclic final drive fixed gear (2). Recover all disassembled parts.

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Front axle system - Final drive hub, steering knuckles, and shafts

Planetary drive and hub - Assemble 1.

Refer to the illustrations on Four-Wheel Drive (4WD) axle - Sectional view (25.102), figure 1 Four-Wheel Drive (4WD) axle - Sectional view (25.102) figure 2, for the positioning of the various parts.

Respect the tightening torques prescribed (see Powered front axle - Torque (25.100) figure 2).

Check the state of the seal, if it should be changed then remove it and turn the hub over on a bench, clean the seat of the seal thoroughly. Set it inside the circumference of the hub and, with tool 380200017 (1), drive it in until the edge of the tool meets the top surface of the hub so as to ensure the assembly stand--in of the oil seal.

Also check the state of the seal on the wheel hub between it and the axle shaft, if it should be changed then take it out and using tool 380200019 insert it until the tool makes contact with the spindle so as to leave the gap.

Assemble the wheel hub and the epicyclic final drive fixed gear.

Progressively tighten the ring nut, using the torque wrench and wrench 380000269 (1) to obtain a torque value of 392 NÂˇm (3469.49 lb in); at the same time, rotate the wheel hub to ensure that the bearings are correctly seated.

Measure the rolling resistance ( Rt ) of the wheel hub using the relative torque wrench, or a torque meter and cord positioned on the base of the wheel disk flange.

Loosen the ring nut by half a turn and measure the rolling resistance (R) as described previously. The difference between the two measurements is the rolling torque value of the wheel hub bearings ( Rc ):

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SEZ25CAP1A-57

SEZ25CAP1A-58

Front axle system - Final drive hub, steering knuckles, and shafts

9. - Rc = Rt - R = 5.9 - 14.7 N·m (52.22 - 130.11 lb in)) or, if measured with a dial torque, - Rc = Rt - R = 4.28 - 10.71 kg (9.44 - 23.61 lb) - If the measurement is less than 5.9 N·m (52.22 lb in) or, if measured with a dial torque, at 4.28 kg (9.44 lb) , replace the relevant parts and repeat the check. 10.

Progressively tighten the ring nut, using the torque wrench and wrench 380000269 (1) to obtain a torque value of 392 N·m (3469.49 lb in); at the same time, rotate the wheel hub to ensure that the bearings are correctly seated.

11.

Carefully secure the ring nut.

12.

Before reassembling the epicyclic final drive casing, carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 2 mm (0.08 in)) along the marked line shown in Bevel gear set and differential carrier - Adjust (25.102) .

13.

Assemble the epicyclic final drive casing, complete with gears.

14.

Fill up the front epicyclic final drive (for recommended products and quantities see Consumables () ).

15.

Mount the steering heads.

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Front axle system - Final drive hub, steering knuckles, and shafts

Planetary drive and hub - Disassemble Front epicyclic final drive with brake NOTE: Front epicyclic final drive removal and installation can be carried out with the axle detached and positioned on the stand 380000251, or with the axle fitted on the tractor. If the operation is performed with the axle fitted on the tractor, a support stand must be positioned under the engine sump. 1.

Position the axle on stand 380000251.

Remove the plug (1) and drain the oil from the epicyclic final drive.

SEZ25CAP1A-59

SEZ25CAP1A-60

SEZ25CAP1A-61

Unscrew all of the epicyclic final drive casing retaining bolts (1).

Using an extractor (1), fitted on the oil drainage plug, detach the epicyclic final drive casing (2).

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Front axle system - Final drive hub, steering knuckles, and shafts

Remove the circlip (1) and extract the external brake disk (2).

SEZ25CAP1A-62

SEZ25CAP1A-63

SEZ25CAP1A-64

Remove the hub (1) and associated brake friction disk.

Take out the retaining bolts and remove the final drive fixed gear (1) using two screws as an extractor.

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Front axle system - Final drive hub, steering knuckles, and shafts

Planetary drive and hub - Assemble Front epicyclic final drive with brake 1.

Refer to the illustrations on Four-Wheel Drive (4WD) axle - Sectional view (25.102), figure 1 Four-Wheel Drive (4WD) axle - Sectional view (25.102) figure 2, for the positioning of the various parts.

Respect the tightening torques prescribed (see Powered front axle - Torque (25.100) ).

Refit the drive fixed gear.

Refit the brake disk hub.

Fit the outer brake disk and secure in position.

Assemble the epicyclic final drive casing, complete with gears.

Fill up the front epicyclic final drive (for recommended products and quantities see Consumables () ).

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Replace 1.

Disassemble the front epicyclic final drive with brake (see Planetary drive and hub - Disassemble (25.108) ) and remove the hub casing (1).

SEZ25CAP1A-65

SEZ25CAP1A-66

SEZ25CAP1A-67

SEZ25CAP1A-68

Remove the seal and fit the pins (1) of tool 380200018.

Carefully clean the seat and position the seal (1), ready for fitting.

NOTE: The external surface on the seal (1), indicated by the arrow, does not require lubrication. 4.

Fit the seal ( (2), 4) fully tightening the screws on tool 380200018 (1).

Remove tool 380200018 from the hub. 47538922 29/05/2013

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Front axle system - Final drive hub, steering knuckles, and shafts

Mount the front epicyclic final drive with brake (see Planetary drive and hub - Assemble (25.108) ).

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Index Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108 Planetary drive and hub - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Planetary drive and hub - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Planetary drive and hub - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Planetary drive and hub - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Planetary drive and hub - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Steering knuckle and king pin - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Steering knuckle and king pin - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wheel hub - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47538922 29/05/2013 EN

SERVICE MANUAL Rear axle system

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Rear axle system - 27

[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[27.126] Spur gear and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

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Rear axle system - 27 Powered rear axle - 100

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Rear axle system - 27 Powered rear axle - 100

TECHNICAL DATA Powered rear axle Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Powered rear axle Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Powered rear axle Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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Rear axle system - Powered rear axle

Powered rear axle - Sealing

MOIL13TR00382HA

Sealing compound application area

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Rear axle system - Powered rear axle

Powered rear axle - Special tools ATTENTION: The operations described in this section can only be carried out with the ESSENTIAL tools indicated by an (X). To work safely and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.

X X X

No. socket

Description

380000569 380001116 380000301 380000569 380000249 380001144 380000237 380000462 380000549 380000403 380001113 380001114

Tractor splitting kit Transmission lifting eyebolt Rotary stand Tractor separation stand Universal pinion installer Crown wheel-differential lifting hook Rear wheel lifting hook Differential servicing stand Slide hammer Rear transmission support Tool for removing and installing the side gearbox Clearance adjustment tool for crown wheel and differential support bearing

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No. previous alternative 297471 290090 292320 293400 293994 292400 291221 292927 -

Rear axle system - Powered rear axle

Tools to be made in garage

MOIL13TR00471HA

Planetary pinion end play adjustment tool

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Rear axle system - Powered rear axle

Material C72 Return temperature Drawn M10 C40 UNI 5588 Uni 6592

1 Caliper 2 Bar 3 Core Plug 4 Normal nut M10 5 Flat washer X M10 A Drill hole after welding nut M12 B Hax nut for M12 screw C Number 4 splits at 90 Â°C D Lock with Loctite thread lock

MOIL13TR00472FA

Pinion bearing pre-load adjustment tool Material C40 hardened

Pinion bearing pre-load adjustment tool a Knurling

Powered rear axle - General specification Planetary ring gear and pinion - Differential Crown wheel ratio Pinion to crown wheel backlash

10/47 = 1:4,7 0.18 - 0.23 mm (0.01 - 0.009 in) 4 planetary gears

Differential Differential lock control: Claw clutch

Acting via the hydraulically engaged front gears

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Rear axle system - Powered rear axle

Differential lock assembly (multi plate wet clutch pack) mm Pinion bearing shim thickness

Crown wheel bearing shim thickness

Planetary thrust washer thickness

4,40; 4,50; 4,60; 4,70; 4,80; 4,85; 4,90; 4,95; 5,00; 5,05; 5,10; 5,15 5,20; 5,25; 5,30; 5,35; 5,40; 5,45; 5,50; 5,55; 5,60; 5,65; 5,70;5,75; 5,80; 5,85; 5,90; 5,95; 6,00; 6,05; 6,10; 6,15; 6,20; 6,30; 6,40; 6,50; 6,60 1 mm (0.039 in)— 0.5 mm (0.020 in) — 0.2 mm (0.008 in) — 0.15 mm (0.006 in)

Differential planetary pinion end play (each)

2,70; 2,75; 2,80; 2,85; 2,90; 2,95; 3,00; 3,05; 3,10; 3,15; 3,20; 3,25; 3,30; 3,35; 3,40; 3,45; 3,50 0.20 - 0.45 mm (0.008 - 0.018 in)

NOTE: The transmission oil capacity and specifications are given in Capacities ().

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Rear axle system - Powered rear axle

Powered rear axle - Static description The rear axle assembly transfers drive from the transmission to the epicyclic final drives through a bevel pinion and crown wheel coupling. The bevel gears are spiral type and are supported by tapered roller bearings. The differential is fitted with four planetary gears and a hydraulic differential lock. The differential lock being of a multi-plate type. Refer to index for the locations of descriptions and operations of differential lock. The epicyclic final reduction gear sets are controlled by the bevel pinion and crown wheel output half-shafts, which also control the brakes.

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Rear axle system - Powered rear axle

Powered rear axle - Drain fluid 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

Remove the drain plug (1) and completely drain all oil into a suitable container.

MOIL13TR00197AA

Replace the cap after draining the oil.

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Rear axle system - Powered rear axle

Powered rear axle - Remove Prior operation: Removing the cab, refer to Cab - Remove (90.150) .Removing the auxiliary fuel tank - refer to Fuel tank - Remove (10.216) .Draining the transmission oil - refer to Powered rear axle - Drain fluid (27.100). 1.

Disconnect the wiring harness, the variant wiring harness (1) and the transmission wiring harness (2) as required to enable the separation of the transmission from the rear axle.

MOIL13TR00349AA

MOIL13TR00198AA

Disconnect the transmission shaft guard (2), removing the screws (1) on the axles, then remove the remaining screws and remove it.

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Rear axle system - Powered rear axle

Remove the snap ring (2) then slide the sleeve (1) on the transmission shaft, from the transmission side.

MOIL13TR00388AA

MOIL13TR00200AA

MOIL13TR00350AA

Remove the central shaft support then slide it from the rear sleeve and remove the transmission shaft. Remember to remove the axle side adjustment shim.

From the right side, disconnect: •

The diverter low pressure pilot pipe (1), on the control valve, free it and move it to the gearbox.

•

Remove the pilot pipe (2) (load sensitivity) ventral control valves (where present) the exhaust pipe (6) and the fuel pipe (5) from the transmission, move the flexible pipes to the gearbox, remove the rigid pipes on both sides and place on a rack.

•

Remove the lubrication line (3), from the gear remote valve to the differential (right part PTO side), PTO lubrication and services control valve, then place it on the rack.

•

Remove the high pressure supply line (4) from both sides and place it to one side.

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Rear axle system - Powered rear axle

From the LH side disconnect: •

The rear brake pipes (1) and place them on the rack.

•

Both pilot pipes (2) from the trailer brake valve (if present).

•

Both supplementary cylinder supply pipes (3) (if present).

•

The pump suction hose (4).

•

From the services control valve (5) the delivery pipe to the heat exchanger, the delivery pipe to the front locking (if present) and the supply pipe to the control valve.

MOIL13TR00351AA

MOIL13TR00352AA

MOIL13TR00353AA

MOIL13TR00354AA

From the right hand side remove: •

The services control valve (1).

•

The tank retaining bracket (4).

From both sides remove:

•

The damper (2)

•

The stabiliser strut and relative support (3)

From the rear side detach: •

The lift vertical struts (1).

•

The lift lower arms (2).

•

The third point and relative support (3).

•

The side stabiliser struts and relative support (4).

Supplementary cylinders (5) (if present) and relative supports. Again on the rear right hand side, detach the quick couplings on the oil tank and relative support. •

10.

Remove the rigid strut (1), the tow bar (2), the rigid hook support (3) with relative support bar.

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Rear axle system - Powered rear axle

11.

12.

Remove the lift lower strut support.

MOIL13TR00201AA

MOIL13TR00202AA

Position wooden wedges (1) between the front axle and front support. These prevent articulation of the front axle.

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Rear axle system - Powered rear axle

MOIL13TR00174FA

13.

Position the splitting kit (3) 380000569 beneath the tractor.

14.

Use the splitting kit supports (2) to support the rear transmission on the stand.

15.

Use the support (1) in the splitting kit to support the transmission on the track.

16.

Check that all necessary hoses tubes and electrical connectors have been disconnected. It may be necessary to disconnect additional items due to other optional equipment that has been installed on the tractor.

17.

WARNING Crushing hazard! Make sure the implement is stable on the blocking prior to assembly. Failure to comply could result in death or serious injury. W0147A

Remove the transmission to rear axle retaining bolts. Remove the rear transmission from the gear assembly and engine.

MOIL13TR00203AA

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Rear axle system - Powered rear axle

18.

19.

With an appropriately sized chain (1) and a set of eyebolts, harness the lift and hook to the hoist.

MOIL13TR00356AA

MOIL13TR00357AA

MOIL13TR00358AA

Unscrew the retaining bolts (1) on the lift with EDC tower and rear transmission control valves.

20.

Raise the assembly and place on a pallet.

21.

Using an appropriately sized hook or belt (2) fix the power takeâ&#x2C6;&#x2019;off to the hoist and pull slightly. Remove the screws (1) fixing the assembly to the transmission housing, then remove the assembly and place on a pallet.

22.

MOIL13TR00355AA

From the LH side, using an appropriately sized belt fasten the axle (2), taking care to balance the weight (tie as close as possible to the longitudinal centre line, to the right). Remove the nuts (1), remove the damper support (if present). Slide out the axle and place on a pallet. Remove the brake disc, the brake and the axle spacer. Do the same on the other side.

NOTE: From the right hand side slide out the axle shaft with the axle, on the other side the axle shaft is held in place by the differential locking. 47538922 29/05/2013

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Rear axle system - Powered rear axle

23.

Support the rear axle on the tractor splitting kit special tool 380000569 and position the support special tool 380000403 underneath the rear axle centre housing.

MOIL13TR00204AA

NOTE: Ensure that the tractor splitting kit support does not obstruct the removal of the four wheel drive hydraulic clutch from underneath the rear axle.

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Rear axle system - Powered rear axle

Powered rear axle - Disassemble Prior operation: Powered rear axle - Remove (27.100) is exceeded.

Remove the rear axle bottom cover.

MOIL13TR00205AA

MOIL13TR00206AA

Remove the inner cover from the four wheel drive assembly.

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Rear axle system - Powered rear axle

Using suitable snap ring pliers, remove the four wheel drive shaft snap ring. (1)series tractor.

MOIL13TR00207AA

MOIL13TR00208AA

MOIL13TR00359AA

MOIL13TR00362AA

Using the slide hammer special tool (1) 380000549 and the locally fabricated adaptor M8 x 1.25 (2), remove the drive shaft from the four wheel drive assembly (3).

NOTE: Helped by another technician, support the four wheel drive gear.

Remove the four wheel drive gear from under the rear axle.

From the under side of the transmission housing, remove the thrust block (3), with a puller, having removed the pin (1), extract the bearing and the hydraulic union for the four wheel drive coupling, these are inside the casting (2).

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Rear axle system - Powered rear axle

10.

Remove the creeper status switches and the switch plungers.

MOIL13TR00209AA

MOIL13TR00210AA

MOIL13TR00211AA

Remove the creeper oil supply tube (1).

Remove the creeper gear selector fork retaining bolt (1).

Never put naked flames close to the air conditioning system.

MOIL13TR00212AA

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Rear axle system - Powered rear axle

11.

Loosely install two M8 x 1.25 x 50 bolts (1) to support the creeper gear.

NOTE: Make sure the creeper gear is in the correct position so the exposed ends of the retaining ring can be seen.

12.

13.

14.

MOIL13TR00213AA

MOIL13TR00214AA

MOIL13TR00326AA

MOIL13TR00325AA

Using suitable snap ring pliers, release the creeper shaft from the casing by expanding the exposed ends of the retaining ring (2) into the groove in the housing and at the same time using a slide hammer special tool (1) 380000549and a locally fabricated adaptor, remove the creeper shaft.

Remove the creeper gear retaining bolts (1) and remove the creeper gear (2).

Using suitable snap ring pliers, remove the snap ring from the pinion shaft (1) and remove the creeper coupler assembly (2) (if fitted).

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Rear axle system - Powered rear axle

15.

16.

17.

18.

Using a suitable socket and bar (1), remove the crushed nut.

MOIL13TR00327AA

MOIL13TR00328AA

MOIL13TR00360AA

MOIL13TR00371AA

Remove the creeper gear (if fitted).

Remove the plastic oil draining container (1) from the transmission housing.

On the LH side, under the container just removed, move the differential locking sensing rod (2) upwards. Move it until the recess marked with (A) reaches the height of the hole (1) so that the lower end of the rod protrudes from the differential LH support (3).

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Rear axle system - Powered rear axle

19.

20.

Remove the differential LH support (3) complete with axle shaft and differential locking assembly, unscrewing the screws (1), also remove the differential locking sensor switch (2) and remove the adjusting shims.

MOIL13TR00361AA

MOIL13TR00372AA

Remove the switch (1) and from the housing switch seat remove the spring (2) and the push rod (3), and from inside the housing the rod (4).

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Rear axle system - Powered rear axle

MOIL13TR00370FA

Support assembly key 1 Detail of cylinder bottom, orientation with screw 3 Bottom - piston orientation pins 5 Differential LH support bearing 7 LH support 9 Needle thrust 11 Differential locking cylinder bottom 12. Locking ring 21.

2 Seals 4 Orientation screws on the piston bottom 6 Support adjusting shims (1-0,5-0,2-0,15 mm) 8 Front locking gear (fixed to the differential housing) 10 Differential lock piston 12 Locking ring

Axle shaft assembly key 1.

Spring retainer bottom

Front gear (fixed to the axle shaft)

Axle shaft

Locking disengagement spring

Retaining snap ring details 1, 2 and 4 on the axle shaft

MOIL13TR00364AA

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Rear axle system - Powered rear axle

22.

23.

24.

25.

Having removed the LH differential support, remove the seeger (1) and extract the axle shaft assembly (3), having removed the screw (2), separating it from the support assembly.

MOIL13TR00363AA

MOIL13TR00365AA

MOIL13TR00366AA

MOIL13TR00330AA

Having separated the two assemblies, take the axle shaft assembly (3) and place it in a press (1), using an appropriately sized tool (2) press down the spring retainer bottom and free the snap ring.

With the press, press down the spring and with a pair of seeger pliers (1) remove the snap ring (2) and release the spring.

From the right hand side, remove the differential support.

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Rear axle system - Powered rear axle

26.

27.

28.

29.

RH support assembly key 1.

Differential housing right support bearing

RH support

Safety fifth wheel

Slewing bearing fastening screws

Bearing pre-load ring nut

Differential lubrication oil holes

MOIL13TR00367AA

MOIL13TR00329AA

MOIL13TR00331AA

MOIL13TR00332AA

Remove the parking brake housing. Refer to Parking brake disks - Remove (33.110)

Using a universal puller (1), partially remove the pinion shaft.

Remove the universal puller and remove the front bearing (1) from the pinion shaft.

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Rear axle system - Powered rear axle

30.

31.

32.

33.

Remove the pinion shaft and remove the inner parts through the parking brake housing.

MOIL13TR00333AA

MOIL13TR00334AA

MOIL13TR00368AA

MOIL13TR00369AA

Remove the bearing (1) from pinion shaft using a hydraulic press.

From the rear, remove the PTO (1) forward shaft.

From the front side, tighten the seeger (1), take the shaft (2) and remove the whole assembly.

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Rear axle system - Powered rear axle

34.

35.

36.

37.

Remove the retaining clip (1) and remove the pin (2) from the PTO clutch oil supply cut off valve.

MOIL13TR00335AA

MOIL13TR00336AA

MOIL13TR00337AA

MOIL13TR00338AA

Remove the PTO ground drive selector fork retaining bolt (1), disengage the PTO ground drive selector fork from the PTO ground drive sliding coupler (2).

Using suitable snap ring pliers, remove the PTO ground drive shaft snap ring (1).

Partially remove the PTO ground drive shaft and remove the snap ring (1).

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Rear axle system - Powered rear axle

38.

39.

40.

41.

While supporting the PTO ground drive gear, remove the PTO ground drive shaft.

MOIL13TR00339AA

MOIL13TR00340AA

MOIL13TR00341AA

MOIL13TR00342AA

Remove the PTO ground drive selector shaft retaining bolts.

Remove the PTO ground drive selector shaft and remove the selector fork from the rear axle housing. Remove the detent plunger and spring (1).

Remove the internal PTO clutch oil supply cut off valve (1).

Next operation: Powered rear axle - Assemble (27.100)

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Rear axle system - Powered rear axle

Powered rear axle - Assemble Prior operation: Powered rear axle - Remove (27.100)

Install the internal PTO clutch oil supply cut off valve PDF (1)

MOIL13TR00342AA

MOIL13TR00341AA

MOIL13TR00340AA

Install the detent plunger and spring (1). Install the PTO ground drive selector shaft and selector fork PDF in the rear axle housing.

Install the PTO drive selector shaft retaining bolts PDF.

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Rear axle system - Powered rear axle

Install the PTO ground drive PDF, the drive shaft and PTO ground drive gear PDF in the rear axle housing.

MOIL13TR00339AA

MOIL13TR00383AA

MOIL13TR00337AA

MOIL13TR00336AA

? PDFand the circlips (1). Install the PTO ground drive shaft PDF

Using suitable circlip pliers, install the PTO ground drive shaft circlip Will you be very angry when I tell you that my ZIP program only works with drag&drop? I canâ&#x20AC;&#x2122;t store the full path (1) PDF

Engage the PTO ground drive selector fork PDF on the PTO ground drive sliding coupler (2). Install the retaining bolt PDF (1) of the PTO ground drive selector fork.

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Rear axle system - Powered rear axle

10.

11.

Install the pin (1) and fit the retaining clip (2) in the PTO clutch oil supply cut off valve PDF.

MOIL13TR00335AA

MOIL13TR00369AA

From the front, install coupling sleeve (2) with the internal bearing, tighten clip (1), insert the shaft in the sleeve.

From the rear, remove the PTO ground drive shaft PDF.

MOIL13TR00368AA

MOIL13TR00384AA

Install the bearing on the pinion shaft.

NOTE: The use of an electronic induction heater will assist in the installation of the bearing without the need for a hydraulic press. 12.

Adjustment of the rear bevel pinion and crown wheel. Refer to Bevel gear - Adjust (27.106)

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Rear axle system - Powered rear axle

13.

14.

Install the creeper coupler assembly (2) and install the internal circlip on the pinion shaft (1) (if fitted).

MOIL13TR00325AA

MOIL13TR00213AA

MOIL13TR00385AA

MOIL13TR00213AA

Position the creeper gear (2). Fit without tightening the two M8 x 1.25 x 50 bolts (1) to support the creeper gear (2).

NOTE: Make sure the creeper gear is in the correct position so the protruding ends of the retaining ring can be seen.

15.

16.

Using suitable circlip pliers, install the creeper shaft into the housing by expanding the exposed ends of the retaining ring (2) into the groove in the housing and at the same time install the creeper shaft.

Remove the creeper gear support bolts (1).

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Rear axle system - Powered rear axle

17.

18.

19.

20.

Install the creeper shaft and bearing support bracket.

MOIL13TR00212AA

MOIL13TR00211AA

MOIL13TR00210AA

MOIL13TR00209AA

Install the creeper gear selector fork retaining bolt (1).

Install the creeper oil supply pipe (1).

Install the switch plungers and the creeper status switches.

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Rear axle system - Powered rear axle

21.

22.

23.

24.

With the aid of another technician, install the clutch assembly (1)in the rear axle housing and in the support.

MOIL13TR00359AA

MOIL13TR00207AA

MOIL13TR00362AA

MOIL13TR00359AA

Using suitable circlip pliers, install and the circlip and the four-wheel drive clutch drive shaft (1).

Working from the underside of the transmission casing, fit the hydraulic fitting in the four-wheel drive clutch (2). Secure it with pin (1), install the bearing and position the thrust washer (3)that will be installed along with the gear.

With aid of another technician, install the gear (1) and the thrust washer, working from the underside of the transmission.

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Rear axle system - Powered rear axle

25.

At the same time, insert the the four-wheel drive shaft, then fit circlip (1) .

26.

Fit the inner cover of the four-wheel drive transfer box.

27.

Thoroughly clean and degrease the mating surfaces (1) of the lower transmission casing and the cover and apply a bead of sealant approx. 2 mm (0.1 in) in diameter to the cover, as shown in: Powered rear axle - Sealing (27.100).

28.

MOIL13TR00207AA

MOIL13TR00387AA

MOIL13TR00205AA

Fit the lower cover to the transmission casing.

Next operation: Powered rear axle - Install (27.100)

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Rear axle system - Powered rear axle

Powered rear axle - Install Prior operation: Powered rear axle - Assemble (27.100)

Clean and carefully degrease the mating surfaces and apply a strip of sealant of approx. 2 mm (0.1 in) in diameter, following the pattern shown in the figure. Align the transmission to the rear axle and install the transmission to rear axle retaining bolts. Tighten screws.

MOIL13TR00386AA

MOIL13TR00406AA

MOIL13TR00358AA

Thoroughly clean and degrease the mating surfaces and apply a bead of sealant measuring approx. 2 mm (0.1 in), for the pattern referring to: Powered rear axle - Sealing (27.100). This goes also for the spacer if it has come away from the axle. Operation to be carried out on both sides.

Taking care to tie the axle (2) with a belt to keep it balanced, reassemble the axle (2), first positioning the brake disk, reassemble the damper support (3) and fix it all with the screws (1). Operation to be carried out on both sides.

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Rear axle system - Powered rear axle

Thoroughly clean and degrease the mating surfaces in the PTO area and apply a bead of sealant measuring approx. 2 mm (0.1 in), for the pattern referring to: Powered rear axle - Sealing (27.100).

MOIL13TR00455BA

MOIL13TR00357AA

MOIL13TR00456BA

MOIL13TR00355AA

Use a hook (2) or appropriately sized belt to fix the power takeâ&#x2C6;&#x2019;off to the hoist. Remove it from the pallet and having placed two guides in the side walls, assemble the assembly, tighten the screws (1).

Thoroughly clean and degrease the mating surfaces in the lift area and apply a bead of sealant measuring approx. 2 mm (0.1 in), for the pattern referring to: Powered rear axle - Sealing (27.100).

Using an appropriately sized chain (1) and eyebolts, harness the lift and hook to the hoist, lift off the pallet and place on the transmission, screw on and tighten the screws, then remove the chain and eyebolts.

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Rear axle system - Powered rear axle

10.

Reassemble the lift lower arm support.

MOIL13TR00201AA

MOIL13TR00354AA

Reassemble the rigid strut (1), the tow bar (2), the rigid hook support (3) with relative support bar.

From the rear side reassemble: •

The lift vertical struts (1).

•

The lift lower arms (2).

•

The third point and relative support (3).

•

The side stabiliser struts and relative support (4).

Supplementary cylinders (5) (if present) and relative supports. Again on the rear right hand side, reassemble the quick couplings on the oil tank and relative support. •

11.

MOIL13TR00353AA

MOIL13TR00352AA

From the right side, reassemble: •

The services control valve (1).

•

The tank retaining bracket.

On both sides reassemble: •

The damper (2).

•

The stabiliser strut and relative support.

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Rear axle system - Powered rear axle

12.

From the LH side reconnect: •

The rear brake pipes (1).

•

Both pilot pipes (2) from the trailer brake valve (if present).

•

Both supplementary cylinder supply pipes (3) (if present).

•

The pump suction hose (4).

From the services control valve (5) the delivery pipe to the heat exchanger, the delivery pipe to the front locking (if present) and the supply pipe to the control valve. Reassemble the rigid and flexible clamps. •

13.

14.

15.

MOIL13TR00352AA

MOIL13TR00350AA

MOIL13TR00200AA

MOIL13TR00199AA

From the right side, reconnect: •

The low pressure pilot pipe (1) diverter, on the control valve.

•

The pilot pipe (2) (load sensitivity) ventral control valves (if fitted) the exhaust pipe (6), the delivery pipe (5) and reassemble the supports and clamps.

•

The lubrication line (3), from the gear remote valve to the differential (right part PDF side), PTO lubrication and services control valve.

•

High pressure supply line (4) on both sides.

Reassemble the four wheel drive drive shaft, sliding it onto the sleeve from the transmission side, reassemble the central shaft support, slide the adjustment shim on the front axle side of the shaft.

Slide the sleeve (2) in the direction shown by the arrow then assemble the seeger (1).

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Rear axle system - Powered rear axle

16.

17.

Reassemble the transmission shaft guard (2), with the screws (1) on the axles, then assemble the remaining screws and tighten them.

MOIL13TR00198AA

MOIL13TR00349AA

Reconnect the wiring harness, the variant wiring harness (1) and the transmission wiring harness (2) as required to enable the separation of the transmission from the rear axle.

Next operation: Fit the right-hand fuel tank - see Fuel tank - Install (10.216). Installing the cab, refer to Cab - Install (90.150) .Top up the transmission with oil of the correct specification.

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Index Rear axle system - 27 Powered rear axle - 100 Powered rear axle - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Powered rear axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Powered rear axle - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Powered rear axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Powered rear axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Powered rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Powered rear axle - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Powered rear axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Powered rear axle - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Rear axle system - 27 Rear bevel gear set and differential - 106

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Rear axle system - 27 Rear bevel gear set and differential - 106

FUNCTIONAL DATA Differential lock Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Bevel gear Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Differential Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Differential lock Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

DIAGNOSTIC Bevel gear Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Differential lock Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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Rear axle system - Rear bevel gear set and differential

Differential lock - Dynamic description

MOIL13TR00922GA

Differential lock engagement A - Static oil (rear differential lock disengaged) B - Oil pressure (rear differential lock engaged)

1 Differential lock status indicator switch 2 Differential lock status indicator rod 3 Front gear fixed to the differential housing

4 Differential lock release spring 5 Front gear fixed to the axle shaft 6 Locking piston

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Rear axle system - Rear bevel gear set and differential

When the differential lock is disengaged, the de-energised solenoid valve is in the drain position and consequently the oil is free to return to the sump. In this condition the spring (4) holds the teeth of the differential lock gears ( (3) and (5) ) apart. On operation of the differential lock control switch, the solenoid valve is energised and opens to allow oil to flow from the low pressure circuit into the control piston (6), where it overcomes the resistance of the spring (4) and moves the piston, thereby engaging the differential lock. As the gear fixed to (5) the axle shaft (3) shifts to mesh with the gear on the differential housing, the lock status indicator rod (2)is pushed upwards, thereby tripping the switch (1) that activates the indicator lamp on the instrument panel.

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Rear axle system - Rear bevel gear set and differential

Bevel gear - Adjust

MOIL13TR00460GA

3 5 7 9

Shim for adjustment of the backlash between the bevel pinion (2)and the crown wheel (6), left side. Planetary gear. Planetary gear end play adjustment shims (3). Front pinion support bearing (2). Pinion (2) support bearing pre-loading adjustment shim ( (7) and (8)).

Pinion.

Differential support bearing pre-loading adjusting nut. Crown wheel. Rear pinion support bearing (2). Pinion bearing pre--load ring nut.

6 8 10

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Rear axle system - Rear bevel gear set and differential

Determining the thickness of the pinion shaft position adjustment shim 1.

Install the front bearing to the pinion shaft.

NOTE: The use of an electronic induction heater will assist in the installation of the bearing without the need for a hydraulic press.

MOIL13TR00384AA

MOIL13TR00333AA

Position the inner parts through the parking brake compartment and install the pinion shaft.

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Rear axle system - Rear bevel gear set and differential

Insert a 6.20 mm (0.24 in) test shim to be mounted. This measurement is indicated as (St). Then assemble the locally fabricated tools ( (2) and (3)) see Powered rear axle - Special tools (27.100), assemble the rear support bearing and the nut.

NOTE: Install a temporary pinion shaft bearings pre-load adjustment test shim, see item (9), figure 1) to determine the required bearing pre-load adjustment shim thickness.

MOIL13TR00389AA

MOIL13TR00329AA

MOIL13TR00390AA

MOIL13TR00457BA

Install the parking brake housing - see Parking brake disks - Assemble (33.110).

Using a suitable adjustable spanner, apply and hold the parking brake.

Using a torque wrench (1) tighten the nut to a torque of 30 N·m (266 lb in) ÷ 50 N·m (443 lb in) while rotating the assembly to settle the components in the pack.

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Rear axle system - Rear bevel gear set and differential

Using a suitable dial gauge (1) and a suitable lever (2), measure the pinion shaft assembly end play. This measurement is indicated as (H4). Determine the pinion shaft pre-load bearing adjustment shim (Sr) as follows: •

Sr = (St - H4) - 0.20 mm (0.01 in)

Where: •

St = 6.20 mm (0.2 in) Thickness of the test shim mounted to assure the pinion shaft assembly end play.

•

H4 = End play measurement of the pinion shaft assembly.

Remove the test shim and install the calculated pinion shaft bearings pre-load shim.

Reassemble the pinion with the components shown in the drawing.

MOIL13TR00391AA

MOIL13TR00392AA

NOTE: The spacer (1) is mounted on machines without creeper, machines with creeper must be fitted with the creeper gear.

10.

Using a suitable adjustable spanner, apply and hold the parking brake.

MOIL13TR00390AA

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Rear axle system - Rear bevel gear set and differential

11.

Install the creeper gear (if fitted).

12.

Install the pinion shaft retaining nut and tighten to a torque of 467 N·m (4133 lb in) ÷ 515 N·m (4558 lb in).

13.

Install the creeper gear (if fitted).

14.

MOIL13TR00439AA

MOIL13TR00440AA

Using a suitable low value torque wrench (1), check the rotational torque of the pinion shaft assembly. This measurement is indicated as (Rp). The rotational torque should be 1 N·m (9 lb in) - 2 N·m (18 lb in) excluding breakaway torque. If the values recorded during the adjustment procedure are outside the specification, adjust the thickness of the pinion shaft adjustment shims and re-check.

NOTE: If the optional components PDF are pre-assembled in the rear axle housing, during the final check the creeper gear rotational torque (Rp) measured from pinion shaft must be much closer to 2 N·m (18 lb in) than to 1 N·m (9 lb in). 15.

Secure the pinion shaft retaining nut in four places.

16.

Install the differential into the rear axle housing.

17.

Install the right hand differential support.

18.

Right Hand assembly 1.

Differential housing right support bearing.

RH support

Safety fifth wheel

Slewing bearing fastening screws

Bearing pre-load ring nut

Differential lubrication oil holes

MOIL13TR00367AA

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Rear axle system - Rear bevel gear set and differential

19.

20.

Torque the retaining bolts to 53 N·m (469 lb in) ÷ 59 N·m (522 lb in)

MOIL13TR00330AA

MOIL13TR00372AA

Locking sensor assembly 1.

Switch

Push rod return spring

Push rod

Sensing rod

NOTE: The sensing rod should be supplied pre-assembled, if not the total length of the rod should be 159 mm (6 in) ÷ 161 mm (6.3 in); to check further, test the switch status, having mounted the differential support with the gear integral with the axle shaft in the engaged and disengaged locking position. 21.

From the LH side, assemble the differential lock sensing assembly

MOIL13TR00371AA

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Rear axle system - Rear bevel gear set and differential

22.

23.

From inside the housing take the rod (4) and move it upwards to the position shown in the figure, kept in place by the push rod (2). Having assembled the support, simply unscrew the switch (1) to allow it to drop into the sensing position.

MOIL13TR00405AA

MOIL13TR00364AA

Assemble the axle shaft assembly: 1.

Spring retainer bottom

Front gear (fixed to the axle shaft)

Axle shaft

Locking disengagement spring

Retaining snap ring details (1), (2) and (4) on the axle shaft

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Rear axle system - Rear bevel gear set and differential

MOIL13TR00370FA

Support assembly 2

Seals.

3 5

Detail of cylinder bottom, orientation with screw (7). Bottom - piston orientation pins. Differential LH support bearing.

4 6

LH support.

9 11

Needle thrust. Differential locking cylinder bottom.

10 12

Orientation screws on the piston bottom. Support adjustment shims ( 1 mm (0.04 in) - 0.5 mm (0.02 in) - 0.2 mm (0.01 in) - 0.15 mm (0.006 in)). Front locking gear (integral with the differential housing). Differential lock piston. Circlip.

24.

Assemble the support assembly (2) insert the differential assembly (3) and tighten with the snap ring (1).

MOIL13TR00363AA

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Rear axle system - Rear bevel gear set and differential

Determining the thickness of the crown wheel backlash and differential support bearing adjustment shims 25.

26.

27.

28.

Using Special tool 380001114 (crown wheel backlash and differential support bearing adjustment tool), (1), loosen the adjustment nut.

MOIL13TR00441AA

MOIL13TR00458BA

MOIL13TR00441AA

MOIL13TR00440AA

Install the left-hand differential support (2) with a test shim of thickness A = 0.7 mm (0.03 in) (1). Tighten the retaining nuts (at least 3 to 120°) to a torque of 53 N·m (469 lb in) ÷ 59 N·m (522 lb in).

Using Special Tool 380001114 (crown wheel backlash and differential support bearing adjustment tool), (1), tighten the adjustment nut.

To obtain a rolling torque (Rt), measured on the pinion with a torque wrench (1): Rt = Rp + ( 0.30 N·m (2.66 lb in) ÷ 0.80 N·m (7.08 lb in)).

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Rear axle system - Rear bevel gear set and differential

29.

Backlash between crown wheel and pinion G 0.18 mm (0.01 in) ÷ 0.23 mm (0.009 in)

•

Determining the crown wheel end float to restore the required clearance. Z = (Gm - 0.20) x 1.33 MOIL13TR00442AA

Where: •

0.20 = nominal average backlash between the pinion and crown wheel teeth

•

1.33 = Ratio between crown wheel end float and the backlash.

•

Shims to be removed (when Gm > 0.20 mm (0.01 in)) or added (when Gm < 0.20 mm (0.01 in)) to the test thickness A.

NOTE: If required, decrease (Z) to the nearest available calculated axial displacement (end float) reading. 30.

Assemble the support (3) with the adjustment shim of the calculated thickness. Torque the fastening nuts (1) to 53 N·m (469 lb in) ÷ 59 N·m (522 lb in). Then remember to remove the switch (2) temporarily to allow the locking engagement sensing rod to drop to the working position.

NOTE: Apply liquid gasket to the first adjustment shim before installing the calculated adjustment shim(s).

31.

MOIL13TR00361AA

MOIL13TR00441AA

Using crown wheel backlash and differential support bearing adjustment tool 380001114 (1), tighten the adjustment nut while checking the rolling torque at the pinion shaft.

NOTE: Rotate the differential assembly while tightening the adjustment nut to seat the bearing rollers on their track.

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Rear axle system - Rear bevel gear set and differential

32.

Using a suitable low value torque wrench (1), check the total rotational torque of the pinion shaft and the differential assembly. This measurement is indicated as "Rt". The total rotational torque should be within the following range excluding breakaway torque: •

Rt = Rp + ( 0.30 N·m (2.66 lb in) ÷ 0.80 N·m (7.08 lb in)).

Where: •

Rp = Rotational torque of the pinion shaft assembly only. MOIL13TR00440AA

34.

35.

Lock the adjustment nut in position with the locking ring (1) and tighten the retaining bolts to a torque value of 27 N·m (239 lb in)).

MOIL13TR00459BA

MOIL13TR00442AA

MOIL13TR00360AA

Using a suitable dial gauge (1), measure the radial movement (backlash) between the pinion and crown wheel perpendicular to the outer edge of a tooth on the crown wheel (2). Repeat the measurement in two further positions 120 °C apart and calculate the average of the three values. This measurement is indicated as (Gm). Gm = 0.18 mm (0.01 in) ÷ 0.23 mm (0.009 in). If the values recorded during the adjustment procedure are outside the specification, adjust the thickness of the crown wheel backlash adjustment shims and re-check.

Reassemble the plastic oil draining container (1) on the transmission housing.

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Rear axle system - Rear bevel gear set and differential

Differential - Disassemble Prior operation: Remove the differential as described in Powered rear axle - Disassemble (27.100).

Using a puller with separator (3) and an appropriately sized metal disk with external diameter less than the diameter of the axle shaft outlet union (1), to counteract the puller central pin; remove the differential housing support bearing from the locking side (left and, proceeding in the same way, from the right side.

MOIL13TR00614AA

MOIL13TR00615AA

MOIL13TR00616AA

Turn the assembly with the right side upwards, remove the differential cage half shell retaining bolts (1) and the ring gear.

Remove the right half shell (1), the end play adjustment shim (2) and the right planetary gear (3).

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Rear axle system - Rear bevel gear set and differential

Also remove the ring gear (1).

MOIL13TR00617AA

MOIL13TR00618AA

MOIL13TR00619AA

MOIL13TR00620AA

Using a hex socket wrench remove the dowel (1), then remove the locking pin (2) from the planetary pinion pins.

Remove the pin (2), from the other side the bushing (4), and then remove the planetary pinions (1) and relative thrust washers (3).

Remove the other pin (3), recover the other two planetary gears (1) and relative washers (2).

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Rear axle system - Rear bevel gear set and differential

Remove the planetary gear (1) and the end play adjustment shim (2).

MOIL13TR00621AA

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Rear axle system - Rear bevel gear set and differential

MOIL13TR00629HA

Differential assembly exploded diagram

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Rear axle system - Rear bevel gear set and differential

1 Support bearings 2 Half shell retaining bolts and ring gear 3 From the half shell retainer and ring gear 80 N·m (708 lb in) ÷ 90 N·m (797 lb in) 4 Planetary retaining pin 5 Planetary retaining pin 6 Planetary retaining bushing 7 Planetary pin retaining pin 8 Pin retaining dowel

9 Planetary gears 10 Planetary thrust washers 11 Planetary end play adjustment shims 12 13 14 15

Planetaries Left differential half shell Right differential half shell Bevel crown wheel

NOTE: When removing, keep the planetary holder pins and the planetary gears together. Next operation: Differential - Assemble (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential - Assemble Prior operation: Differential - Disassemble (27.106)

The required end play between the planetaries and the planetary gears is 0.20 mm (0.01 in) รท 0.45 mm (0.02 in). โ ข

Average clearance Gm.= 0.30 mm (0.01 in) .

Install a test shim (1) ( S1p).

Assemble the left differential housing assembly (2) as described in the figure (without the locking pin).

MOIL13TR00622AA

MOIL13TR00557BA

Using the "Planetary pinion end play adjustment tool" to be manufactured locally, see: Powered rear axle - Special tools (27.100) Having assembled all the pieces of the tool (2), slide it into the right axle shaft compartment (1) as far as it will go, making sure that the tool passes the planetary gear (3). Then, with the bar, push the cap into the pliers which, widening, push into the hole in the planetary, allowing it to move upwards and downwards, then tighten the lock nut.

NOTE: Make sure that after assembling the tool the planetary is in contact with the planetary gears, twist a few times to set the gears in position.

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Rear axle system - Rear bevel gear set and differential

Hold the bar down and with a 1/20 depth gauge take two offset measurements of 180 ° between the upper part of the tool and the differential housing. Calculate the average of the two measurements. This measurement is identified with ( H1).

MOIL13TR00626AA

MOIL13TR00627AA

MOIL13TR00622AA

MOIL13TR00618AA

Lift the bar upwards so that the planetary is in contact with the differential housing. Using the depth gauge again, take two offset measurements of 180 ° between the tool surface and the differential housing. Calculate the average of the two measurements. This measurement is identified as ( H2). The axial clearance limitation shim to insert is: S1 = [(H1 - H2) + S1p] - Gm

Reassemble the components of the half shell (2), reassemble with the calculated shim (1).

Assemble the pin (2), then mount the dowel (1).

NOTE: Apply LOCTITE® 243 to the locking dowel.

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Rear axle system - Rear bevel gear set and differential

Reassemble the ring gear and the other half shell (3) with the relative planetary and the test shim ( S1p), insert only some of the screws (2) and tighten them.

10.

Again using the "Planetary pinion end play adjustment tool" to be manufactured locally, see: Powered rear axle - Special tools (27.100)

11.

Assemble the tool similarly to assemble on the other half shell, keeping the bar downwards, and with a 1/20 depth gauge take two offset measurements of 180 Â° between the upper part of the tool and the differential housing. Calculate the average of the two measurements. This measurement is (H1).

MOIL13TR00625AA

MOIL13TR00626AA

MOIL13TR00627AA

NOTE: Make sure that after assembling the tool the planetary is in contact with the planetary gears, twist a few times to set the gears in position.

12.

13.

Lift the bar upwards so that the planetary is in contact with the differential housing. Using the depth gauge again, take two offset measurements of 180 Â° between the tool surface and the differential housing. Calculate the average of the two measurements. This measurement is identified with ( H2).

The end play shim must be: S1 = [(H1 - H2) + S1p] - Gm

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Rear axle system - Rear bevel gear set and differential

14.

15.

Remove the half shell, re-assemble with the calculated shim (1) and tighten all the screws to a torque of 14 NÂˇm (124 lb in).

MOIL13TR00628AA

MOIL13TR00384AA

Mount the support bearings on both sides of the differential unit.

NOTE: The use of an electronic induction heater will assist in the installation of the bearing without the need for a hydraulic press. Next operation: Install the differential as described in Powered rear axle - Assemble (27.100)

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Rear axle system - Rear bevel gear set and differential

Differential lock - Remove Prior operation: Powered rear axle - Drain fluid (27.100) is exceeded.

Remove the retainer (1), lift the RH steps, open the battery compartment using the knob (2) and disconnect the negative battery cable.

MOIL12TR00670AA

MOIL13TR00344AA

Raise the rear of the tractor with a hydraulic jack, put a mechanical stand under the tow bar, with a pneumatic gun remove the LH rear wheel retaining nuts, and subsequently take off the wheel.

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Rear axle system - Rear bevel gear set and differential

Place the tool (1) inside the cab and connected it to the hoist using ropes or chains and tension them slightly so that the weight of the cab does not weigh down on the dampers.

MOIL12TR00682AA

MOIL12TR00684AA

MOIL12TR00682AA

MOIL13TR00400AA

Disconnect the LH dampers from the tractor, release the stabiliser strut (1).

Having disconnected the damper system from the rear LH side, place wooden blocks between the bottom of the cab and the transmission. If possible, leave the cab suspended from the hoist (1), otherwise rest the cab on the wooden blocks.

Using the hoist and an appropriately sized belt or a hydraulic jack with an appropriately sized hook, harness the LH gearbox. Loosen the gearbox (2) and remove the damper (1), disconnect the gearbox with the stabiliser strut support, then place the whole assembly on a pallet.

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Rear axle system - Rear bevel gear set and differential

Using a screwdriver (1) or seeger pliers, remove the seeger (2).

MOIL13TR00401AA

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Rear axle system - Rear bevel gear set and differential

MOIL13TR00407CA

Differential assembly key

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Rear axle system - Rear bevel gear set and differential

1 Differential lock indicator switch 2 Push rod spring 3 Push rod 4 Differential lock indicator rod 5 Differential housing LH support 6 Differential piston assembly retaining seeger and axle shaft in LH support 7 Locking cylinder bottom A Push rod retaining area if the push rod is moved upwards by hand, when removing the LH support

8 Front gear return spring (11) 9 Spring axle shaft to spring bottom retaining snap ring 10 Locking piston 11 Front gear (fixed to the axle shaft) 12 Spring retainer bottom 13 Front gear (fixed to the differential housing) 14 Needle thrust B Warning rod support surface with locking disengaged, the two inclined planes on either side allow the front gear to move forwards and backwards without being impeded by the rod

Remove the axle shaft joined to: •

Locking cylinder bottom

•

Locking piston

•

Needle thrust

•

Front gear (fixed to the axle shaft)

•

Front gear return spring

•

Spring retainer bottom

•

Spring bottom retaining snap ring

MOIL13TR00402AA

10.

11.

Having removed the axle shaft assembly remove: •

Locking cylinder bottom

•

Locking piston

•

Needle thrust

Take the axle shaft (3) place in a press (1), using an appropriately sized tool (2) press down the spring retainer bottom to free the snap ring.

MOIL13TR00365AA

MOIL13TR00366AA

With the press, press down the spring and with a pair of seeger pliers (1) remove the snap ring (2) and release the spring.

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Rear axle system - Rear bevel gear set and differential

12.

Looking inside the support (3) the gear (2) does not come out because the sensing rod (1) prevents its passage.

NOTE: The image shows only the support but it is in any case surrounded by the housing.

13.

MOIL13TR00403AA

MOIL13TR00404AA

MOIL13TR00405AA

Using a screwdriver, hold the sensing rod (1) and pull it upwards.

14.

By moving the sensing rod (3) upwards, the situation shown in the figure occurs. This is held by the push rod (2) and the switch (1) so that the lower end comes out of the support.

15.

In this case the last front gear can be removed from the differential locking, the one fixed to the differential housing.

Next operation: Differential lock - Assemble (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential lock - Assemble Prior operation: Differential lock - Remove (27.106) .

Having completed the necessary repairs and replacements, reassemble all the components as described below. NOTE: For the correct orientation of the various parts, refer to: Differential lock - Remove (27.106) 1.

Take the axle shaft (3) and slide onto the differential side: •

the front gear

•

the spring

•

the spring retainer

using the press (1) and the tool (2), press the spring to below the retaining ring groove.

MOIL13TR00365AA

MOIL13TR00366AA

Use the pliers (1) to assemble the snap ring (2), then release the spring.

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Rear axle system - Rear bevel gear set and differential

Re-assemble on the axle shaft: •

Needle thrust

•

Locking piston

Locking cylinder bottom • Grease the seal gaskets with transmission oil.

Reassemble the front gear (1) fixed to the differential housing.

Reassemble the differential assy.

MOIL13TR00402AA

MOIL13TR00401AA

MOIL13TR00405AA

MOIL13TR00406AA

To drop the sensing rod (3) simply unscrew the switch (1) if this does not drop, move the push rod (2) with a screwdriver.

Thoroughly clean and degrease the mating surfaces and apply a bead of sealant measuring approx. 2 mm (0.1 in), for the pattern referring to: Powered rear axle - Sealing (27.100).

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Rear axle system - Rear bevel gear set and differential

10.

11.

Using the hoist and an appropriately sized belt or a hydraulic jack with an appropriately sized hook, harness the LH gearbox. Reassemble the gearbox (2) with the support of the stabiliser strut, together with the damper (1). Torque the screws

MOIL13TR00400AA

MOIL12TR00682AA

MOIL12TR00684AA

Position the tool (1) inside the cab and connect it to the hoist using ropes or chains, tension slightly, remove the wooden blocks under the cab, then slightly lower the cab so that the stabiliser strut and damper fixing holes line up with those on the cab.

Reconnect the stabiliser strut (1) and relative damper, torque the screws. Loosen the hoist chains and remove the tool.

Using a hydraulic jack, replace the LH wheel, tighten the screws, remove the jack stand under the tow bar and lower the machine, removing the jack.

MOIL13TR00344AA

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Rear axle system - Rear bevel gear set and differential

12.

Connect the negative battery cable, close the battery compartment using the knob (2) lower the steps and fasten with the retainer (1).

MOIL12TR00670AA

Next operation: Powered rear axle - Drain fluid (27.100)

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Rear axle system - Rear bevel gear set and differential

Bevel gear - Troubleshooting Problem Possible Cause Noisy rear axle when the Pinion and/or crown wheel bearing misadtractor is moving, and justment also with transmission in neutral (not originating from final drives) Worn or incorrectly adjusted sun and planetary gears

Noisy rear axle with tractor under load and upon release

Remove rear axle housing, replace worn parts and adjust the differential gear backlash Excess differential side gears to half-shaft Remove rear axle housing and replace damaged parts spline backlash Excess bevel pinion to crown wheel back- Remove rear axle housing and adjust pinlash ion and crown wheel bearings correctly Remove rear axle housing, replace worn parts and adjust differential gear backlash correctly Insufficient pinion and/or crown wheel Remove rear axle housing and adjust pinion and crown wheel bearings correctly bearing backlash Insufficient bevel pinion to crown wheel Remove rear axle housing and adjust crown wheel bearings correctly tooth backlash Faulty or defective inner component

Noisy rear axle and over-heating

Correction Remove rear axle housing and adjust pinion and crown wheel bearings correctly

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Rear axle system - Rear bevel gear set and differential

Differential lock - Troubleshooting Problem Differential lock not engaging

Differential lock not disengaging

With differential lock engaged, the differential lock does not disengage when brake pedals are pressed

Possible Cause Low rear axle oil level

Correction Top up to the correct oil level

Blocked oil filter Faulty hydraulic pump Faulty differential lock switch Power supply not reaching solenoid valve: detached or damaged electrical connectors, faulty remote switch Differential lock control solenoid valve stuck on discharge Oil leaks through the seals with consequent pressure drop: cylinder piston oil supply line seals Faulty differential lock-unlock switch

Replace the oil filter Overhaul or replace pump Replace the differential lock switch Restore electrical connection and replace faulty parts. Overhaul or replace solenoid valve Overhaul or replace solenoid valve

Power supply not reaching solenoid valve: detached or damaged connectors, faulty remote switch Differential lock control solenoid valve stuck on delivery Oil leaks through the seals with consequent pressure drop: cylinder piston or supply line seals Faulty differential lock switch (connected to the brake pressure switches/foot pedal switches)

Repair electrical connection and replace faulty parts

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Replace faulty seals Replace switch

Overhaul or replace solenoid valve Replace faulty seals Replace the differential lock switch

Index Rear axle system - 27 Rear bevel gear set and differential - 106 Bevel gear - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bevel gear - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Differential - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Differential - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Differential lock - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Differential lock - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Differential lock - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Differential lock - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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Rear axle system - 27 Planetary and final drives - 120

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Rear axle system - 27 Planetary and final drives - 120

TECHNICAL DATA Planetary final drive General specification Main specifications of final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Planetary and final drives Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Final drive housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Driving wheel shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

DIAGNOSTIC Planetary final drive Troubleshooting Final drive fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Rear axle system - Planetary and final drives

Planetary final drive - General specification Main specifications of final drives Type Reduction ratio Thickness of planet pinion shims

planetary with three planet pinions with straight teeth 1 : 6,75 1 mm (0.0394 in)± 0.3 mm (0.0118 in) See adjustment in Driving wheel shaft - Remove Adjusting end float of planet carrier (27.120) and Driving wheel shaft - Assemble (27.120) − 0.2 - 0.5 mm (0.0079 - 0.0197 in) axle shaft end float 4.5 mm (0.1772 in)— 4.6 mm (0.1811 in) — 4.7 mm (0.1850 in) — 4.8 mm (0.1890 in) — 4.9 mm (0.1929 in) — 5 mm (0.1969 in) — 5.1 mm (0.2008 in) — 5.2 mm Thickness of adjustment shims for planet carrier end float (0.2047 in) — 5.3 mm (0.2087 in) — 5.4 mm (0.2126 in) — 5.5 mm (0.2165 in) — 5.6 mm (0.2205 in) — 5.7 mm (0.2244 in) — 5.8 mm (0.2283 in)

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Rear axle system - Planetary and final drives

Planetary and final drives - Sectional view

MOIL13TR00866HA

WHEEL AXLES

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Rear axle system - Planetary and final drives

1 2 3

15 16 17

Thrust washer Pin retaining circlip Planet carrier

Inner bearing

19 20 21 22 23 A B a

Internal oil seal Planet gear Needle bearing Spacer Shim Detail showing planet gear / pin Detail showing planet carrier adjustment Fill with grease

Right axle shaft Axle housing spacer Axle housing retaining studs/bolts Tightening torque Planet carrier 250 N·m (2213 lb in) ÷ 165 N·m (1460 lb in) . Planet carrier/axle shaft retaining bolt Tightening torque 228 N·m (2018 lb in) to 252 N·m (2230 lb in) Axle housing Wheel Hub Wheel hub oil seal Grease cup Outer bearing Planet carrier end float adjustment spacer Spacer Axle housing retaining studs/bolts Tightening torque 250 N·m (2213 lb in) to 165 N·m (1460 lb in) Left axle shaft

Planet gear pins

Outer oil seal assembly position 2.5 mm (0.10 in) to 3 mm (0.12 in) Planet carrier end float 0.2 mm (0.01 in) to 0.5 mm (0.02 in)

5 6 7 8 9 10 11 12

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Rear axle system - Planetary and final drives

Planetary and final drives - Exploded view

MOIL13TR00942GA

Exploded view of the final drive components 1 2 3 4 5 6 7 8

Left axle shaft Right axle shaft Bolt securing planet carrier to axle shaft Safety washer Safety washer Spacer Bearing Planet carrier end float adjustment shim

9 10 11 12 13 14 15 16

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Side pinion carrier Crown Wheel Spacer Grease pipe Final drive housing Wheel axle Oil seal Bearing

Rear axle system - Planetary and final drives

Final drive housing - Remove 1.

Raise the steps using the lever (1), open the battery compartment using the lever (2) and connect the negative battery cable.

Lock the front wheels using chocks.

Detach the vertical tie--rod (1) and the LH anti--swing rod (2).

MOIL12TR00670AA

MOIL12APL0038AA

MOIL12APL0041AA

WLAPL4S10C110A

Raise the rear part of the tractor and position a fixed stand under the flex bar support.

Unscrew the retaining bolts and remove the rear LH wheel.

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Rear axle system - Planetary and final drives

Take out the screws (1) fastening the cab support bracket to the gearbox.

Slightly raise the cab and position a suitable piece of wood between the cab and the lift casing, making sure not to crush any piping or wiring during the procedure.

Take out the plug (1) and drain the oil from the gearbox--rear transmission casing.

MOIL12APL0039AA

MOIL13TR00197AA

MOIL12APL0040AA

Connect the final drive casing to suitable equipment for lifting and retaining. Take out the retaining bolts and remove the final drive casing from the transmission casing.

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Rear axle system - Planetary and final drives

Final drive housing - Assemble WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

To refit the final drive casing, proceed as follows: 1.

Before refitting the casings, supports and covers, carefully clean and degrease the mating surfaces and apply a bead of sealing compound of approximately 2 mm (0.079 in) in diameter, as shown in: Powered rear axle Sealing (27.100) .

Fit the final drive assembly using suitable equipment for lifting and retaining. Tighten the bolts to a torque of: 150 NÂˇm (1328 lb in) to 165 NÂˇm (1460 lb in) .

Remove the strip of wood and secure the rear cab support bracket to the gearbox taking care to avoid crushing any piping or wiring.

Tighten the transmission-gearbox oil drain plug (1).

MOIL13TR00197AA

WLAPL4S10C110A

Install the left-hand rear wheel.

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Rear axle system - Planetary and final drives

Fit the stabiliser strut (2)and the vertical rod (1).

MOIL12APL0038AA

Remove the chocks from under the front wheels.

Connect the battery negative cable, put the battery cover back on and lower the right-hand steps.

Fill the transmission/gearbox casing with oil.

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Rear axle system - Planetary and final drives

Driving wheel shaft - Remove Prior operation: Final drive housing - Remove (27.120)

Position the final drive casing (1) on a rotating stand.

Remove the spacer and the ring gear.

SEZ27CAP1A-105

SEZ27CAP1A-106

SEZ27CAP1A-107

Remove the bolt (1) securing the planet carrier to the axle shaft and recover the safety plate.

Extract the support (1) from the driven gears and remove the end float adjuster shim from the support.

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Rear axle system - Planetary and final drives

Using a suitable puller, withdraw the axle shaft and recover the rear bearing.

Remove the front (1) and rear seal, then recover the front bearing and remove the grease fitting cap.

Remove also the grease fitting, check that its is good working order and replace it if necessary.

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SEZ27CAP1A-108

SEZ27CAP1A-109

Rear axle system - Planetary and final drives

Driving wheel shaft - Assemble Prior operation: Driving wheel shaft - Remove (27.120)

To refit the final drive casing, proceed as follows: A.

For the correct orientation of the various parts, refer to the exploded view in Planetary and final drives - Sectional view (27.120)

Fit the rear seal (1)using a suitable installer.

Apply plenty of grease to the front face of the seal behind the bearing housing (1) .

Fit the front bearing (3) and the relative seal (2) using a suitable installer, observing the assembly dimension 2.5รท3 mm (0.098รท0.118 in). Fill the space between the bearing and seal with grease.

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MOIL13TR00936AA

MOIL13TR00937AA

Rear axle system - Planetary and final drives

Install the axle shaft (2) and the grease fitting (1).

MOIL13TR00938AA

MOIL13TR00939AA

MOIL13TR00940AA

SEZ27CAP1A-110

Fit the planet carrier (4) and the relative adjustment shim (5). Fit the thrust washer (3) and the tab washer (2) and tighten the bolt (1) to a torque of 228÷252 N·m (2018.0÷2230,4 lb in) .

Fit the ring gear (1) and spacer (2).

Adjust the end float of the gear support as follows.

Using a dial gauge (1), check that the end float of the planet carroer (2) is 0.2÷0.5 mm (0.008÷0.020 in); if not, adjust the shim thickness.

Next operation: Final drive housing - Assemble (27.120)

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Rear axle system - Planetary and final drives

Planetary final drive - Troubleshooting Final drive fault diagnosis Problem Final drives are noisy while the tractor is moving, even when the gears are in neutral.

Possible Cause Correction Incorrect adjustment of wheel axle shaft Remove the final drive casing and adjust support bearings. the bearings ( Driving wheel shaft - Assemble (27.120)). Internal part faulty.

Remove the final drive housing and replace the damaged parts. Excessive clearance between wheel axle Remove the final drive housing and replace shaft spline and epicyclic final drives. the damaged parts.

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Index Rear axle system - 27 Planetary and final drives - 120 Driving wheel shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Driving wheel shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Final drive housing - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Final drive housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Planetary and final drives - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Planetary and final drives - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Planetary final drive - General specification Main specifications of final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Planetary final drive - Troubleshooting Final drive fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Rear axle system - 27 Spur gear and final drives - 126

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Rear axle system - 27 Spur gear and final drives - 126

SERVICE Driving wheel shaft and gears Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Rear axle system - Spur gear and final drives

Driving wheel shaft and gears - Disassemble Prior operation: Planetary final drive - Assemble (27.120)

Remove retaining ring (1). Slide out the pivot pins and recover the gears complete with the needle bearings. Remove the thrust washer.

1b0o2004061047

Next operation: Driving wheel shaft and gears - Assemble (27.126)

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Rear axle system - Spur gear and final drives

Driving wheel shaft and gears - Assemble Prior operation: Driving wheel shaft and gears - Disassemble (27.126) 1.

Insert the thrust washer first on the driven gear holder. To reassemble, reverse the order of the disassembly operations.

Install the retaining ring (1).

1b0o2004061047

Next operation: Driving wheel shaft - Adjust (27.120)

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Index Rear axle system - 27 Spur gear and final drives - 126 Driving wheel shaft and gears - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Driving wheel shaft and gears - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47538922 29/05/2013 EN

SERVICE MANUAL Power Take-Off (PTO)

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Power Take-Off (PTO) - 31

[31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[31.116] Three-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

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Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104

TECHNICAL DATA Rear electro-hydraulic control General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Rear electro-hydraulic control Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dynamic description PTO shiftable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Synchronized Power Take-Off (PTO) drive shaft and gears Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SERVICE Synchronized Power Take-Off (PTO) controls Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Power Take-Off (PTO) hand control Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Power Take-Off (PTO) control valve Adjust Oil bypass valve spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

DIAGNOSTIC Rear electro-hydraulic control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - General specification ISO - main data for PTO with electro-hydraulic engagement Standard version Optional version

Type (two functions)

Engagement and control Direction of rotation (from tractor rear) Speed Selection Engine speed with PTO at 540 RPM Engine speed with PTO at 540E RPM Engine speed with PTO at 1000 RPM PTO speed with engine at max. power rpm of 2300 RPM: - for 540 RPM PTO- for 540E RPM PTO- for 1000 RPM PTO Synchronized PTO revolution speed: - for 540 RPM PTO- for 540E RPM PTO- for 1000 RPM PTO Diameter of splined output shaft: - 540 RPM - 540E RPM - 1000 RPM

540 RPM, 1000 RPM PTO 540 RPM, 540E RPM, 1000 RPM PTO 540 RPM, 540E RPM, 1000 RPMPTO with ground speed synchronized PTO Independent of tractor ground speed Synchronized with gearbox Electro-hydraulic: controlled by way of a knob located to the right of the driving position Mechanical: controlled by way of a knob located to the left of the driving position Clockwise by way of the hand lever located to the rear and left of the driverâ&#x20AC;&#x2122;s seat 1938 RPM 1535 RPM 1926 RPM 641 RPM 809 RPM 1194 RPM 8.41 revs per wheel revolution 10.62 revs per wheel revolution 15.88 revs per wheel revolution 34.925 mm (1.375 in)(6 splines) 34.925 mm (1.375 in) (6 splines) 34.925 mm (1.375 in) (21 splines)

Rear electro-hydraulic control - General specification NAR - main data for PTO with electro-hydraulic engagement Standard version Optional version Type Direction of rotation (from tractor rear) Speed Selection Engine speed with PTO at 540 RPM Engine speed with PTO at 540E RPM Engine speed with PTO at 1000 RPM PTO speed with engine at max. power rpm of 2300 RPM: - for 540 RPM PTO- for 540E RPM PTO- for 1000 RPM PTO Diameter of splined output shaft: - 540 RPM - 540E RPM - 1000 RPM

540 RPM, 1000 RPM PTO 540 RPM, 540E RPM, 1000 RPM PTO Electro-hydraulic: controlled by way of a knob located to the right of the driving position clockwise To change the splined output shaft ( 540 RPM and 1000 RPM ) operate the hand lever located to the left of the driver's seat ( 540E RPM ) 1938 RPM 1535 RPM 1926 RPM 641 RPM 809 RPM 1194 RPM 34.925 mm (1.375 in)(6 splines) 34.925 mm (1.375 in) (6 splines) 34.925 mm (1.375 in) (21 splines)

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Special tools Lifting hook for the power take-off. 380000243Clutch spring press. 380000258 Hand grip (for use with tool 50135).

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Dynamic description When the ground speed PTO is selected, the rear transmission selector fork shifts the sliding coupling (7) to the engaged position, thereby connecting the pinion drive shaft (6) to the PTO input shaft (8). In this way, drive is transmitted from the driving gear, keyed onto the pinion shaft, to the end plate of the PTO clutch via the driven gear and the input shaft (8). The drive train by-passes the PTO clutch and drives the output shaft in accordance with the speed selected by the operator.

MOIL13TR00967FA

Operation of the PTO clutch oil bypass valve.-.Ground speed PTO engaged 1

Ground speed PTO engagement lever.

5 7 9

Oil line from services control valve to bypass valve Oil line from bypass valve to the PTO clutch PTO engaging sleeve Spool control rod on bypass valve

6 8 10

11 A

Bypass valve spool Discharge oil

12 B

Lever retaining screw (1) Tightening torque 45 56 NÂˇm (398 - 496 lb in) PTO engagement oil bypass valve. Drive shaft from pinion Driven shaft Pin and lock nut tightening torque 10 - 16 NÂˇm (89 - 142 lb in) Spool guide screw Oil at clutch engagement pressure 17 - 18 bar (246 - 261 psi)

When ground speed PTO is engaged, the PTO brake solenoid is automatically disengaged by the controller. The spool of the PTO clutch oil bypass valve (11) is shifted by the selector lever (9)so as to block the oil flow from the bypass valve. This additional safety feature will prevent engagement of the PTO clutch. Any pressurised oil remaining behind the PTO clutch piston will be drain to tank through the PTO oil bypass valve.

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Power Take-Off (PTO) - Rear electro-hydraulic control

MOIL13TR00966FA

Operation of the PTO clutch oil bypass valve - Ground speed PTO disengaged and PTO clutch engaged 1

Ground speed PTO engagement lever.

5 7 9

Oil line from services control valve to bypass valve Oil line from bypass valve to the PTO clutch PTO engaging sleeve Spool control rod on bypass valve

6 8 10

11 A

Bypass valve spool Discharge oil

12 B

On disengagement of the ground speed PTO, the spool of the PTO bypass valve (11) is shifted by the selector lever (9) and the PTO brake solenoid valve is automatically activated by the controller. On engagement of the PTO clutch, the controller deactivates the PTO brake (not shown in the illustration) and the oil can flow to the bypass valve and on to the PTO clutch (4) .

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Dynamic description PTO shiftable The PTO brake (1) and engagement solenoid (2) are housed in the low pressure distribution block on the left hand side of the rear axle. When the PTO is not in use, the PTO brake solenoid is energised and the PTO clutch solenoid is de-energised.

MOIL13TR00776AA

The oil from the services control valve enters the PTO assy from the hole (1), through the one-way valve which stops the oil from going to the clutch, permitting only discharge, and through the restrictor (4) it reaches the clutch, (this ensures a more modulated packing of the clutch, contrary to the discharge which must be immediate). 1. Pressurised oil inlet 17 - 18 bar (246 - 261 psi) 3. One-way valve cap 5. Core Plug

2. Ball 4. Throttle

MOIL13TR01014AA

At the restrictor, the oil acts on the lubrication start valve, also at minimum pressure (this at the start of modulation) and presses the spring increasing lubrication. 1. Lubrication start spool 3. Core Plug

2. Spring

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Power Take-Off (PTO) - Rear electro-hydraulic control

MOIL13TR01015AA

The oil from the services control valve goes at the same time to the clutch and also acts on the lubrication reduction valve spool (1) which is normally open and offers maximum lubrication. This to a pressure of approx. 14 bar (203 psi) at which the spring (3) starts to compress and moves the spool to the left to reduce lubrication, which will be complete at the clutch working pressure 17 - 18 bar (246 - 261 psi). 1. Lubrication reduction spool 3. Spring

2. Spring retainer plate 4. Core Plug

MOIL13TR01013AA

The Belleville springs push the piston into the housing and disengage the operation on the clutch disks and the outlet shaft. When the piston is seated in the housing there is a small gap between the rear of the washer and the clutch piston housing. It should be noted that when the PTO disengages, the oil flow rate required to lubricate the clutch disks is less than that needed with the PTO engaged, as described in the following sequence. Consequently, reducing the oil flow rate to the clutch disks when not required, a greater flow rate can be sent to the other hydraulic circuits in operation.

MOIL13TR00777AA

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Power Take-Off (PTO) - Rear electro-hydraulic control

MOIL13TR00963JA

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Power Take-Off (PTO) - Rear electro-hydraulic control

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Power Take-Off (PTO) - Rear electro-hydraulic control

PTO control clutch disengaged B. Oil at a pressure > 14 bar (203 psi) A. Oil discharged to the reservoir D. Lubrication oil at reduced flow rate C. Oil at a pressure of 17 - 18 bar (246 - 261 psi) 2. PTO Brake E. Lubrication oil at a high flow rate 4. Lubrication reduction valve 1. PTO clutch 6. Lubrication oil inlet 3. Brake ducking inlet 8. Lubrication start valve 5. Low pressure oil inlet 17 - 18 bar (246 - 261 psi) 10. Clutch hub bearing 7. One-way valve 9. Throttle In this phase, where the PTO solenoid valve is not energised and the PTO brake solenoid valve is energised, the lubrication start valve (8) is fully up and leaves a small passage for the lubrication oil. The oil passes through the lubrication reduction valve (4) which is normally open and reaches the clutch hub bearing area, lubricating the PTO clutch at a reduced flow rate.

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Power Take-Off (PTO) - Rear electro-hydraulic control

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Power Take-Off (PTO) - Rear electro-hydraulic control

MOIL13TR00964JA

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Power Take-Off (PTO) - Rear electro-hydraulic control

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Power Take-Off (PTO) - Rear electro-hydraulic control

PTO Soft Start (initial engagement) B. Oil at a pressure > 14 bar (203 psi) A. Oil discharged to the reservoir D. Lubrication oil at reduced flow rate C. Oil at a pressure of 17 - 18 bar (246 - 261 psi) 2. PTO Brake E. Lubrication oil at a high flow rate 4. Lubrication reduction valve 1. PTO clutch 6. Lubrication oil inlet 3. Brake ducking inlet 8. Lubrication start valve 5. Low pressure oil inlet 17 - 18 bar (246 - 261 psi) 10. Clutch hub bearing 7. One-way valve 9. Throttle Engagement of the PTO is considered as a two phase operation. When the PTO is operated the engagement solenoid is energised and the brake solenoid disengaged. The oil in the low pressure hydraulic circuit passes through the solenoid valve and through the lubrication start valve (8), at minimum pressure, depresses the spring placing the spool in the maximum lubrication position, through the lubrication stop valve (4), also in the maximum lubrication position, reaches the clutch piston and starts to press the disks. This phase required maximum lubrication.

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Power Take-Off (PTO) - Rear electro-hydraulic control

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Power Take-Off (PTO) - Rear electro-hydraulic control

MOIL13TR00965JA

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Power Take-Off (PTO) - Rear electro-hydraulic control

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Power Take-Off (PTO) - Rear electro-hydraulic control

PTO soft start (final engagement) B. Oil at a pressure > 14 bar (203 psi) A. Oil discharged to the reservoir D. Lubrication oil at reduced flow rate C. Oil at a pressure of 17 - 18 bar (246 - 261 psi) 2. PTO Brake E. Lubrication oil at a high flow rate 4. Lubrication reduction valve 1. PTO clutch 6. Lubrication oil inlet 3. Brake ducking inlet 8. Lubrication start valve 5. Low pressure oil inlet 17 - 18 bar (246 - 261 psi) 10. Clutch hub bearing 7. One-way valve 9. Throttle When the pressure supplied to the piston nears 14 bar (203 psi) the pressure applied to the terminal surface of the lubrication reduction valve (4) moves the latter against the spring and reduces the lubrication oil flow rate to the value passing through the valve heading towards the clutch disks to the value; meanwhile the lubrication start valve (8) does not change its position. Less lubrication of the clutch plates is necessary after the initial stage of engagement and this process limits the demand of the PTO on the lubrication circuit oil which is also used for other circuits on the tractor. The pressure applied to the rear of the piston now continues to increase, up to 17 - 18 bar (246 - 261 psi), to maintain a suitable tightening pressure on the clutch disks and through the clutch control the PTO outlet shaft.

PTO clutch brake The band type clutch brake operates automatically. It applies when the PTO clutch is being disengaged (braking start) and stops braking when the clutch is completely engaged. When working with high inertia implements it is possible to keep the brake disengaged by pressing the switch (1) located on the right hand post. When engaging the PTO clutch, the brake control oil is sent to the reservoir from when the respective solenoid valve is in the discharge position (de-energised) and consequently there is no contact of the actuating piston (2). When the PTO control clutch is being disengaged, the solenoid valve is energised and opens, diverting oil from the low pressure circuit onto the piston (2). The piston acts on the outside of the clutch (1).

MOIL13TR00778AA

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Power Take-Off (PTO) - Rear electro-hydraulic control

Synchronized Power Take-Off (PTO) drive shaft and gears Sectional view

MOIL13TR01078GA

1. PTO clutch driving shaft. 2. Bearing snap ring (3) on the housing 3. Front shaft bearing (6) 4. Bearing snap ring (3) on the shaft (6) 5. Synchronised PTO output gear 6. Synchronised PTO drive shaft 7. Seeger 8. Synchronised PTO output gear 9. Bearing snap ring (10) on the shaft (6) 10. Rear shaft support bearing (6) 11. Bearing snap ring (10) on the housing

Key to components 19. Spool guide screw (16). 20. Synchronised PTO engagement sliding sleeve control fork and (31) spool control rod (16) 21. Fork retaining dowel (20) 22. Fork retainer and pin (23)on the rod (31) 23. Clip 24. Rod connecting fork (31) to the spool (16) 25. Locknut 26. Supply coupling 27. Delivery coupling to clutch 28. Clutch supply pipe 29. PTO housing supply coupling 47538922 29/05/2013

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Power Take-Off (PTO) - Rear electro-hydraulic control

Key to components 30. Control valve supply pipe (18) 31. Fork coupling rod (20) and Control Valve (18) 32. Synchronised PTO engagement sleeve 33. Pins 34. Clip

12. Synchronised PTO engagement sleeve 13. Synchronised PTO output shaft 14. Ring gear 15. Pinion gear 16 Oil bypass valve spool 17. Hydraulic coupling retaining dowels 18. Oil bypass valve: from the service control valve to the PTO clutch

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Power Take-Off (PTO) - Rear electro-hydraulic control

Synchronized Power Take-Off (PTO) controls - Adjust WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

1. On the left, next to the operator, the synchronised PTO coupling lever(1), the flexible cable (2) leaves the cab through the hole (3).

Move the lever fully backwards to the rear of the machine.

MOIL13TR01077BA

MOIL13TR01070AA

On the right, in the rear of the transmission, near the gearboxes there is the external control lever (1) of the synchronised PTO engagement yoke. Rotate the lever upwards all the way along the disengaged synchronised PTO stroke.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Move the screw (1) against the lever.

MOIL13TR01071AA

MOIL13TR01072AA

MOIL13TR01073AA

MOIL13TR01074AA

Loosen the nuts on the end of the flexible cable (1). Fit the flexible cable (1) on the reaction bracket and tighten the nuts.

Fit the pin (2) on the end of the flexible cable, in the hole on the lever and lock with the split pin (1).

Move the screw (1) into contact with the sensor feeler. Unscrew the screw 3 more turns.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Tighten the adjusting screw lock nut (1).

MOIL13TR01075AA

NOTE: check the adjustment using a tester. Place the tester in resistance test mode and connect the rods to the sensor wires. Assisted by a technician, on the machine, moving the coupling lever fully back (synchronised PTO disengaged) to fully forward (synchronised PTO engaged). — synchronised PTO disengaged (the tester will show 560 Ω) — synchronised PTO engaged (the tester will show 2760 Ω) Check that the sensor commutation does not correspond to the end of the adjusting screw compression, if this happens unscrew the screw 1 more turn.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) hand control - Adjust WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

The PTO gear lever (1) is in the cab on the right hand side of the operator. The flexible gear control cable (2) leaves the cab through the rear right hand side of the hole (3).

MOIL13TR01076BA

MOIL13TR01066AA

The lever (1) can move in three positions. Place the lever in the central position.

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Power Take-Off (PTO) - Rear electro-hydraulic control

On the rear left hand side of the tractor you will find the external PTO gear lever (3). This also has three positions: - 540 RPM in the highest position - 540E RPM (with three speeds) or neutral (with two speeds) in the central position - 540 RPM in the lowest position Place this lever also in the central position. Place the cable fixing bracket at a distance (L) = 186 mm (7 in) from the yoke fixing hole.

MOIL13TR01067AA

MOIL13TR01068AA

MOIL13TR01069AA

Tighten the two screws (2) fixing the bracket (1) to a tightening torque of 10 NÂˇm (89 lb in).

Move the small fork (3) until the pin enters, fix in position with the tab (2) and tighten the lock nut (1).

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Power Take-Off (PTO) - Rear electro-hydraulic control

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) control valve - Adjust Oil bypass valve spool

MOIL13TR01041FA

1. 2. 3. 4. 5. 6.

7. Spool hex recess 8. Synchronised engagement sleeve 9. Rear pin 10. Rear pin stopper 11. Yoke lock nut G = 0 - 0.2 mm clearance between the rear surface of the control valve and the spool surface

Synchronised sleeve coupling lever Front pin retaining stopper Oil by-pass control rod Front pin Yoke Control valve spool

With the power take−off disengaged (sleeve fully forward).

Mount all the components on the rod between the engagement lever and the yoke; screw the latter on the control valve spool, without tightening the lock nut.

Using a suitably sized spanner, screw or unscrew the end of the spool (7) until there is a clearance of G = 0 - 0.2 mm between the end of the control valve and the spool

Tighten the lock nut to a torque of 10 - 16 N·m (89 142 lb in).

NOTE: apply a layer of LOCTITE® sealant and thread lock on the threaded part of the yoke.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Troubleshooting Problem Possible Cause Transmission oil level low. The independent PTO (governed by the flywheel) fails to work Clogged oil filter. Hydraulic pump faulty. PTO engagement switch faulty. Lack of power supply to the solenoid valve: connections loose or damaged, contact or faulty. Solenoid valve (2) Rear electro-hydraulic control - Dynamic description (31.104) controlling the PTO clutch locked on delivery to brake. Oil leakage through the seals with consequent pressure drop: seal of the manifold, control plunger, etc. (refer to Three-speed rear Power Take-Off (PTO) - Sectional view (31.116) Rear electro-hydraulic control - Dynamic description (31.104) The independent PTO PTO engagement switch faulty. (governed by the flywheel) stays on. Solenoid valve ( (1), fig. 1, Rear electro-hydraulic control - Static description (31.104)) governing the PTO clutch locked on delivery to clutch. The PTO clutch drags. Solenoid valve (2) Rear electro-hydraulic control - Dynamic description (31.104) governing the brake locked on delivery to clutch. Brake Three-speed rear Power Take-Off (PTO) - Sectional view (31.116) of the worn PTO. Clutch plates damaged or deformed.

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Correction Top up oil.

Replace filter. Overhaul or replace the pump. Replace switch. Check electrical connections and replace defective parts. Overhaul or replace solenoid valve.

Replace damaged seals.

Replace switch.

Overhaul or replace solenoid valve.

Replace the brake. Replace discs.

Index Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104 Power Take-Off (PTO) control valve - Adjust Oil bypass valve spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Power Take-Off (PTO) hand control - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Rear electro-hydraulic control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rear electro-hydraulic control - Dynamic description PTO shiftable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Rear electro-hydraulic control - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear electro-hydraulic control - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear electro-hydraulic control - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear electro-hydraulic control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Synchronized Power Take-Off (PTO) controls - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Synchronized Power Take-Off (PTO) drive shaft and gears - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

FUNCTIONAL DATA Two-speed rear Power Take-Off (PTO) Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Power Take-Off (PTO) case Remove PTO assy from transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Power Take-Off (PTO) clutch brake Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Power Take-Off (PTO) speed rate selector control Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Sectional view Two-speed NAR PTO

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

MOIL13TR01236JA

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41

43 45 47 49

51 53 55

57 59 61 63 65 67 69 71 73 75

Key to exploded view of power take-off 540 RPM, 540E RPM, 1000 RPM Hydraulic circuit connection 2 Sealing Brake piston cap 4 Cap retaining snap ring 6 O-rings O-rings Brake piston pad 8 Driving shaft 540 RPM, 1000 RPM 10 Driving gear 540E RPM Snap ring 12 Bearing support Front shaft support bearing (8) 14 Seal ring Seal ring 16 PTO cover Rear shaft support bearing (8) 18 O-rings O-rings Piston outer seal 20 Clutch return spring 22 Piston inner seal Clutch piston 24 6 plain steel plates Outer clutch housing 26 6 friction plates Clutch cover snap ring 28 Lid Clutch cover Plate retaining spring 30 Circlip 32 Clutch hub bearing Clutch hub 34 Shielding support O-rings 36 Output shaft retaining seeger PTO output shaft 1000 RPM 38 Oil seal Driven shaft rear support bearing Thrust washer 40 Bearing retaining internal seeger (38) Driven gear 1000 RPM 42 Transmission cover retaining screw with tightening torque 192 - 232 N·m (1699 - 2053 lb in) Driven gear bush 1000 RPM 44 Sliding drive coupling sleeve 1000 RPM, 540 RPM Engagement gear 540 RPM, 1000 RPM 46 Driven gear 540 RPM Thrust washer 48 Driven shaft front support bearing Driven gear bush 540 RPM 50 Driven shaft component retaining nut with tightening torque 280 - 309 N·m (2478 - 2735 lb in) (when tightened, stake in two positions) 52 Driven shaft Selector fork control rod 540 RPM, 1000 RPM Push rod locknut 54 Push rod 56 Lever push rod (55) Gearbox control lever 540 RPM, 1000 RPM, see: Two-speed rear Power Take-Off (PTO) - Adjust (31.114) 58 Speed selector rod. O-rings Fork return spring 60 Clutch oil pressure pipe 62 Lubrication pipes Reducer valve for clutch pack lubrication Lubrication opening spring 64 Lubrication control spool 66 Gear selector fork retaining pin on rod (57) Clip Pressurized oil inlet pipe Rod fixing dowel (57) on bearing support (12) 68 70 Lubrication start control valve Restrictor (controls modulation) 72 One-way valve (for rapid clutch discharge) Support retaining screw (74) with tightening torque 8 - 10 N·m (71 - 89 lb in) 74 Clip Lever support (55) 76 Lever pin (55) with transmission mechanism Swing bearing support

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) case - Remove PTO assy from transmission WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Remove the split pin (1), raise the steps using the knob (2), remove the battery cover and disconnect the negative cable.

MOIL12TR00670AA

SEZ31CAP2A-27

MOIL13TR00197AA

Remove the tow bar and the top link on the threepoint linkage device (1).

Take out the plug (1) and drain oil from the gearboxtransmission casing.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Remove the PTO speed sensor (1).

SEZ31CAP2A-29

MOIL13TR01019AA

SEZ31CAP2A-30

SEZ31CAP2A-31

Fit a sling on the tow support (1), remove the PTO casing retaining bolts and detach the tow support.

Take out the four retaining bolts (1), remove the guard (2) on the PTO terminal.

Unscrew the unions and remove the pipes (1) from the PTO casing.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Hitch the PTO unit (1) to the hook with the chain. Tension the hoist, place two guide pins and remove the four retaining bolts from the PTO unit to the transmission/gearbox casing and remove the PTO unit.

MOIL13TR01022AA

Next operation: Power Take-Off (PTO) case - Disassemble (31.114)

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) case - Disassemble WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Power Take-Off (PTO) case - Remove (31.114) 1.

Secure the PTO in the vice on the workbench and detach the lifting hook with chain. Remove the securing ring and unscrew the driven shaft lock nut (1). Then remove the reaction bracket from the gearbox flexible cable (2).

MOIL13TR01024AA

MOIL13TR01025AA

MOIL13TR01027AA

Unscrew the Allen key (2) from the fork support rod (1) and (3) positioned on the support.

Using an appropriately sized punch, beat the front of the rod (1) then remove it.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Remove: 1.

Fixed sleeve

Sliding Sleeve

Driven gear 540E RPM

Shim

Bushing

Selector fork 540E RPM

MOIL13TR01028AA

MOIL13TR01017AA

MOIL13TR01018AA

MOIL13TR01029AA

Using a pair of appropriately sized seeger pliers, remove the locking seeger (3) from the PTO brake, then remove the following components: 1.

End cap seal O-ring

Brake cylinder bottom

Cap retaining snap ring

Piston seal O-ring

Brake piston and relative brake pads

Remove the cover from the clutch (1) completed with lubrication reduction valve, removing the screws (2).

Recover the support bearing (1) from the clutch hub and the hub (2).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

10.

11.

Using a pair of appropriately sized seeger pliers, remove the clutch locking seeger (1) on the output shaft.

MOIL13TR01030AA

MOIL13TR01031AA

Recover the clutch assembly (1).

With a pair of seeger pliers, remove the seeger from the drive shaft (1).

MOIL13TR01032AA

MOIL13TR01033AA

Recover the drive shaft (5) and its parts: 1.

Driving gear 540E RPM

Seals

O-rings

Drive shaft rear support bearing.

Drive shaft 540 RPM, 1000 RPM

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

12.

13.

14.

15.

Fit the extractor with separator (4) on the driving shaft (2) and secure in the vice. Fit the extractor (1) and connect it to the extractor (4). Position a plate on the end of the shaft (2) and tighten the extractor until the bearing (3) is extracted.

SEZ31CAP2A-53

MOIL13TR01034AA

MOIL13TR01035AA

Unscrew the four locking screws from the inner support (1).

From the PTO inner support (4), remove all components: 1.

One-way valve (upper) and restrictor

Lubrication start valve

Gearbox lever poppet ball

Inner support

Drive shaft front support bearing

Use pliers to remove the snap ring from the output shaft, use a pair of seeger pliers to remove the seeger from the bearing and extract the seals using appropriate keys. Then recover the components. See exploded view:

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

MOIL13TR01040GA

Key to components 1. 2. 3. 4. 5. 6. 7. 8. 9.

6-spline output shaft 540 RPM, 540E RPM Snap ring holding the end of the output shaft O-ring Driven shaft Main support Engagement fork 540 RPM, 1000 RPM Shaft front support bearing Shim Bushing

10. 11. 12. 13. 14. 15. 16. 17. 18.

Driven gear 540 RPM Sliding drive coupling sleeve 540 RPM, 1000 RPM Fixed Sleeve Driven gear 1000 RPM Bushing Shim Bearing retaining seeger Bearing Oil seal

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

16.

17.

18.

19.

Using an appropriately sized punch, remove the spring pin (1) from the outer lever (2) on the gear box and recover the O-ring, the retaining ring (3), the pin (4) and the lever (5).

MOIL13TR01036AA

MOIL13TR01037AA

SEZ31CAP2A-49

SEZ31CAP2A-50

Using a suitable tool, recover the O-rings, hydraulic connectors and the alignment studs. Remove the plug (1) and the oil level (2).

Remove the snap ring (1) the clutch disk reaction ring (2) and the driving and driven clutch disks.

Fit the spring press tool 380000243 (1) on the disk support (2) as shown in the figure, tighten the tool 380000243 to compress the internal spring.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

20.

21.

22.

When possible, remove the snap ring (1) using a screwdriver. Loosen the nut (2) and disassemble the tool 380000243 (3).

SEZ31CAP2A-13

SEZ31CAP2A-51

SEZ31CAP2A-52

Using a compressed air gun, expel the piston (1) from the disk support (2).

Remove and check the condition of all parts, replacing O--ring seals (1) and (2), if necessary.

Next operation: Power Take-Off (PTO) case - Assemble (31.114)

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) case - Install WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Clean the rear contact surface between the transmission/gearbox casing and the PTO casing.

Re-tighten the two guide pins used for disassembly on the PTO unit.

Clean the surface of the PTO casing and apply a 2 mm (0.079 in) diameter bead of the sealing compound indicated in Basic instructions (), following the instructions given in the figure.

Hitch the PTO unit (1) to the hook with the chain.

Place the PTO unit in front of the transmission casing, use a hoist to move the parts into position and insert on the centring pins.

Remove the chain and fix the PTO with the locking screws, with a tightening torque of 84 - 103 NÂˇm (743 - 912 lb in).

Remove the centering pins.

MOIL13TR01023AA

MOIL13TR01022AA

SEZ31CAP2A-31

Reconnect the hydraulic fittings (1) to the PTO casing.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

10.

11.

12.

Re-assemble the guard (2) on the end of the PTO with the screws (1), with a tightening torque of 23 28 NÂ·m (204 - 248 lb in).

SEZ31CAP2A-30

MOIL13TR01019AA

SEZ31CAP2A-29

SEZ31CAP2A-27

Sling the tow support (1) and reassemble.

Re-assemble the speed sensor (1), reconnect the connector and reassemble any brackets or clamps.

Re-assemble the third point (1) and the tow bar.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

13.

14.

Re-assemble the oil drain plug (1) and top up the transmission with oil following the specifications illustrated in: Capacities ().

MOIL13TR00197AA

MOIL12TR00670AA

Reconnect the negative battery cable, replace the cover and fix with the knob (2), then replace the steps and fix with the split pin (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) case - Assemble

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch brake - Remove WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Remove the split pin (1), raise the steps using the knob (2), remove the battery cover and disconnect the negative cable.

MOIL12TR00670AA

SEZ31CAP2A-27

MOIL13TR01019AA

Remove the tow bar and the top link on the threepoint linkage device (1).

Sling the tow support (1), remove the fixing screws on the PTO casing and remove the tow support.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Remove the right--hand vertical tie-rod (1) from the lift arm, to have more room for subsequent disassembly.

SEZ31CAP2A-24

SEZ31CAP2A-4

SEZ31CAP2A-25

SEZ31CAP2A-26

Remove the brake cover retaining snap ring (1).

Remove the cover (1) with a screwdriver.

Screw the screw (1) on the brake piston threaded hole (2) and extract the piston using pliers.

Next operation: Power Take-Off (PTO) clutch brake - Install (31.114)

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch brake - Install WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Power Take-Off (PTO) clutch brake - Remove (31.114) 1.

Refit the PTO brake assembly: 1.

End cap seal O-ring

Brake cylinder bottom

Cap retaining snap ring

Piston seal O-ring

Brake piston and relative brake pads

MOIL13TR01017AA

SEZ31CAP2A-24

MOIL13TR01019AA

Reconnect the right--hand vertical tie-rod (1) to the lift arm.

Refit the pick--up hitch hook (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Refit the tow bar and the three-point linkage device top link (1).

SEZ31CAP2A-22

MOIL12TR00670AA

Reconnect the negative cable and fit the battery guard, fix with the knob (2) and lower the steps, fixing into place with the split pin (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) speed rate selector control - Adjust WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Adjusting the transmission idler at two speeds 540 RPM and 1000 RPM 1.

Mount the 21 spline shaft (1) to 1000 RPM and lock with the seeger (2).

MOIL13TR01063AA

MOIL13TR01065AA

Screw the dowel (1) until the engagement yoke (3) moves the sleeve (4) against it. Unscrew the dowel (1)1/2 a turn then tighten the lock nut (2) .

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Index Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114 Power Take-Off (PTO) case - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Power Take-Off (PTO) case - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Power Take-Off (PTO) case - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Power Take-Off (PTO) case - Remove PTO assy from transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Power Take-Off (PTO) clutch brake - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Power Take-Off (PTO) clutch brake - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Power Take-Off (PTO) speed rate selector control - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Two-speed rear Power Take-Off (PTO) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Power Take-Off (PTO) - 31 Three-speed rear Power Take-Off (PTO) - 116

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Power Take-Off (PTO) - 31 Three-speed rear Power Take-Off (PTO) - 116

TECHNICAL DATA Three-speed rear Power Take-Off (PTO) General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Three-speed rear Power Take-Off (PTO) Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Power Take-Off (PTO) speed rate selector control Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - General specification Ground speed PTO Type Control PTO Shaft Revolutions Per Wheel Revolution: - with range engaged at 540 RPM - with range engaged at 540E RPM - with range engaged at 1000 RPM

Mechanical actuation of a sliding coupler selector From the pinion shaft 8.41 revs per wheel revolution 10.62 revs per wheel revolution 15.88 revs per wheel revolution

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - Sectional view ISO three-speed PTO

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

MOIL13TR00961JA

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41

43 45 47 49 51 53 55

57 59 61 63 65 67

Key to the exploded view of the power take-off 540 RPM, 540E RPM, 1000 RPM Hydraulic circuit connection 2 Seal Brake piston cap 4 Cap retaining snap ring 6 O-rings O-rings Brake piston pad 8 Driving shaft 540 RPM, 1000 RPM 10 Driving gear 540E RPM Snap ring 12 Bearing support Front shaft bearing (8) 14 Seal ring Seal ring 16 Cover (PTO) Rear shaft support bearing (8) 18 O-rings O-rings Piston outer seal 20 Clutch piston Piston return spring 22 Piston inner seal 24 6 plain steel plates Outer clutch housing 26 6 friction plates Clutch cover snap ring 28 Lid Clutch cover Plate retaining spring 30 Snap Ring 32 Clutch hub bearing Clutch hub 34 Shielding support O-rings 36 Output shaft retaining snap ring Output P.T.O. shaft 38 Oil seal Driven shaft rear support bearing Thrust washer 40 Bearing retaining internal snap ring (38) Driven gear 1000 RPM 42 Transmission cover retaining screw with tightening torque 192 - 232 NÂˇm (1699 - 2053 lb in) Driven gear bush 1000 RPM 44 Sliding drive coupling sleeve 540 RPM, 1000 RPM Engagement gear 540 RPM, 1000 RPM 46 Driven gear bush 540 RPM Driven gear 540 RPM 48 Thrust washer Driven gear 540E RPM 50 Driven shaft front bearing Thrust washer 52 Coupling sleeve 540E RPM Engagement gear 540E RPM 54 Driven gear bush 540E RPM 56 Driven shaft Driven shaft component retaining nut with tightening torque 280 - 309 NÂˇm (2478 - 2735 lb in) (when tightened, stake in two positions) 58 Speed selector rod. O-rings 60 Selector fork 540 RPM, 1000 RPM Selector fork 540E RPM 62 Oil pressure pipe to clutch Reducer valve for clutch pack lubrication Lubrication pipes 64 Lubrication opening spring 66 One-way valve (for rapid clutch discharge) Oil pressure inlet pipe Lubrication start control spool 68 Choke valve (controls the modulation of the clutch engagement)

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - Sectional view NAR three speed PTO systems

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

MOIL13TR00960JA

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41

43 45 47 49 51 53 55

57 59

61 63 65 67 69 71 73 75 77 79 81 83

Key to the exploded view of the power take-off 540 RPM, 540E RPM, 1000 RPM Hydraulic circuit connection 2 Seal Brake piston cap 4 Cap retaining snap ring 6 O-rings O-rings Brake piston pad 8 Driving shaft 540 RPM, 1000 RPM 10 Driving gear 540E RPM Snap ring 12 Bearing support Front shaft bearing (8) 14 Seal ring Seal ring 16 Cover (PTO) Rear shaft support bearing (8) 18 O-rings O-rings Piston outer seal 20 Clutch piston Piston return spring 22 Piston inner seal 24 6 plain steel plates Outer clutch housing 26 6 friction plates Clutch cover snap ring 28 Lid Clutch cover Plate retaining spring 30 Snap Ring 32 Clutch hub bearing Clutch hub 34 Shielding support O-rings 36 Output shaft retaining snap ring PTO output shaft 540 RPM, 540E RPM 38 Oil seal Driven shaft rear support bearing Thrust washer 40 Bearing retaining internal snap ring (38) Driven gear 1000 RPM 42 Transmission cover retaining screw with tightening torque 192 - 232 N·m (1699 - 2053 lb in) 44 Gear driven bush 1000 RPM Sliding drive coupling sleeve 540 RPM, 1000 RPM Engagement gear 540 RPM, 1000 RPM 46 Gear driven bush 540 RPM Driven gear 540 RPM 48 Thrust washer Driven gear 540E RPM 50 Driven shaft front bearing Thrust washer 52 Coupling sleeve 540E RPM Engagement gear 540E RPM 54 Driven gear bush 540E RPM 56 Driven shaft Driven shaft component retaining nut with tightening torque 280 - 309 N·m (2478 - 2735 lb in) (when tightened, stake in two positions) Selector fork control rod 540 RPM, 1000 RPM 58 Gear change mechanism support with terminal change 60 Push rod Main gear lever. 540 RPM, 1000 RPM, see: Three-speed rear Power Take-Off (PTO) Adjust (31.116) Push rod locknut 62 Safety washer 64 Lever push rod (59) PTO output shaft 1000 RPM 66 Speed selector rod. O-rings 68 Fork return spring (68) Engagement fork 1000 RPM, 540 RPM 70 Selector fork 540E RPM Clutch oil pressure pipe 72 Lubrication pipes Reducer valve for clutch pack lubrication Lubrication opening spring 74 Lubrication control spool 76 Split pin Lever pin (59) 78 Support retaining screw (58) with tightening Split thrust washer torque 8 - 10 N·m (71 - 89 lb in) 80 One-way valve (for rapid clutch discharge) Oil pressure inlet pipe Lubrication start control spool 82 Choke valve (controls the modulation of the clutch engagement) 84 Gear selector fork retaining pin 540 RPM, Clip 1000 RPM

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Adjusting the transmission idler at three speeds 540E RPM, 540 RPM and 1000 RPM 1.

Turn the lever (1) upwards to engage the gear 540 RPM

MOIL13TR01059AA

MOIL13TR01060AA

MOIL13TR01061AA

Adjust the dowel (1) to leave a clearance (G) = 0,4 - 0,5 mm between the dowel and the pin (4), fit the plate (3) and screw on the nut (2).

NOTE: Take care to ensure that the tooth (3) on the plate (1) slots into the groove (4) on the dowel (2).

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Move the lever (1) downwards to engage the gear 1000 RPM.

MOIL13TR01062AA

MOIL13TR01063AA

MOIL13TR01064AA

Mount the 21-spline shaft (1) and lock into place with the seeger (2).

5. Pull on the lever (1) to check it is not pre-loaded by the pin (2) and that there is minimum clearance, if it is pre-loaded screw the dowel 1/4 of a turn. Tighten the nut (3) with a torque of 75 - 93 NÂ·m (664 - 823 lb in).

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Index Power Take-Off (PTO) - 31 Three-speed rear Power Take-Off (PTO) - 116 Power Take-Off (PTO) speed rate selector control - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Three-speed rear Power Take-Off (PTO) - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Three-speed rear Power Take-Off (PTO) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Three-speed rear Power Take-Off (PTO) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

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SERVICE MANUAL Brakes and controls

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Brakes and controls - 33

[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[33.220] Trailer brake hydraulic control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

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Brakes and controls - 33 Hydraulic service brakes - 202

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Brakes and controls - 33 Hydraulic service brakes - 202

FUNCTIONAL DATA Brakes Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Brakes and controls - Hydraulic service brakes

Brakes - Sectional view service brakes on front axle. (1). Oil inlet union. (2). Bleed screw. (3). Plug on the hub to access bleed screw on brake cylinder. (4). Brake cylinder/final drive ring gear support. (5). Wear disk. (6). Reaction plate. (7). Disk unit retaining circlip. (8). Brake disc. (9). Seal. (10). Brake piston.

SEZ33CAP1B-1

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Index Brakes and controls - 33 Hydraulic service brakes - 202 Brakes - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Brakes and controls - 33 Parking brake or parking lock - 110

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Brakes and controls - 33 Parking brake or parking lock - 110

TECHNICAL DATA Parking brake or parking lock Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Parking brake or parking lock Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Hand brake lever Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Parking brake disks Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

DIAGNOSTIC Parking brake or parking lock Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Special tools Tool No. 380000982

Description

Alternative previous No. -

Parking Brake Alignment tool

Parking brake or parking lock - Torque

BVF0949B_399

BVF0823B

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Static description The parking brake is controlled mechanically. It acts on the rear pinion gear shaft and is controlled through a hand lever located to the left of the operators seat. When the parking brake control lever is raised, the cable acts on the actuator forcing the pads against the brake discs which are splined to the tractor rear pinion shaft.

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Brakes and controls - Parking brake or parking lock

Hand brake lever - Travel adjust Prior operation: Parking brake disks - Install (33.110) NOTE: Adjustment of the parking brake control lever travel should be performed each time the parking brake is serviced or repaired and when the (idle) travel of the lever is excessive.

Proceed as follows : 1.

Lock the front wheels appropriately.

Lift the rear of the tractor using suitable means, so that the wheels are slightly off the ground.

Raise the parking brake control lever to the third notch on the quadrant.

Release the lock nut (1) and screw the adjusting screw (2) until the wheels lock.

BVF0837A

Lower the parking brake control lever and ensure that the wheels can rotate freely.

Apply the parking brake several times to check that the assembly does not get blocked or operate abnormally.

Tighten the locknut (1) and lower the tractor.

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Brakes and controls - Parking brake or parking lock

Parking brake disks - Remove Prior operation: Removing the auxiliary fuel tank - refer to Fuel tank - Remove (10.216) .Draining the transmission oil - refer to Powered rear axle - Drain fluid (27.100).

Remove the split pin (2) and the segment (1) from the parking brake lever.

BVE0950A

BVF0949A

Remove the parking brake housing.

Next operation: Parking brake disks - Disassemble (33.110)

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Brakes and controls - Parking brake or parking lock

Parking brake disks - Assemble Prior operation: Parking brake disks - Disassemble (33.110) 1.

Install the parking brake lever on the shaft (1).

BVF0827B

BVF0829A

BVF0830A

Install the O-ring (1) and the spacer (2).

Install the parking brake lever and spring (1).

NOTE: Remove the paint to reveal the alignment marks. NOTICE: When installed, the parking brake control lever must be centred on the shaft, referring to the alignment marks.

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Brakes and controls - Parking brake or parking lock

Using suitable snap ring pliers, install the snap ring (1).

BVF0825A

BVF0824A

BVF0823B

Rotate the parking brake housing by 180 Â°. Install the friction and steel plates (1).

Install the safety tabs (1) and retaining bolts. Tighten the retaining bolts to the prescribed torque. Hold the retaining bolts in place with the safety tabs (1).

Next operation: Parking brake disks - Install (33.110)

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Brakes and controls - Parking brake or parking lock

Parking brake disks - Disassemble Prior operation: Parking brake disks - Remove (33.110) 1.

Place the parking brake housing into a suitable vice. Free the safety tabs (1) and remove the retaining bolts (2).

BVF0823A

BVF0824A

BVF0825A

Remove the friction and steel plates (1).

Rotate the parking brake housing by 180 Â°. Using suitable snap ring pliers, remove the snap ring (1).

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Brakes and controls - Parking brake or parking lock

Remove the parking brake lever and spring (1).

BVF0826A

BVF0827A

BVF0828A

Remove the parking brake lever shaft (1).

Remove the spacer (2) and O-ring (1).

Next operation: Parking brake disks - Assemble (33.110)

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Brakes and controls - Parking brake or parking lock

Parking brake disks - Install Prior operation: Parking brake disks - Assemble (33.110)

Thoroughly clean and degrease the mating surfaces and apply a bead of sealant measuring approx. 2 mm (0.079 in), to the rear transmission housing.

BVF0952A

BVF0986A

BVF0987A

Using special tool 380000982 (2), align the brake discs (1) on the pinion shaft.

Install the special tool 380000982 (1), between the brake pads (2).

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Brakes and controls - Parking brake or parking lock

Position the parking brake assembly complete with the special tool 380000982 (1), between the brake discs on the pinion shaft. Remove the special tool (1) while installing the parking brake assembly.

BVF0988A

BVF0949B_399

BVE0950A

Tighten the retaining bolts to the prescribed torque.

Top up the transmission with oil of the correct specification - refer to Powered rear axle - General specification (27.100).

Install the segment (2) and the split pin (1) in the parking brake lever.

Next operation: Fit the right-hand fuel tank - see Fuel tank - Install (10.216). Adjusting the parking brake cable - refer to Hand brake lever - Travel adjust (33.110).

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Troubleshooting Problem Parking brake or parking lock - Inefficient (33.110-G.10.C.70) Parking brake or parking lock - Not disengage (33.110-G.10.B.30)

Possible Cause

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Correction

Index Brakes and controls - 33 Parking brake or parking lock - 110 Hand brake lever - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Parking brake disks - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Parking brake disks - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Parking brake disks - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Parking brake disks - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Parking brake or parking lock - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Parking brake or parking lock - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Parking brake or parking lock - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Parking brake or parking lock - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Brakes and controls - 33 Trailer brake hydraulic control - 220

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Brakes and controls - 33 Trailer brake hydraulic control - 220

TECHNICAL DATA Trailer brake hydraulic control General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Trailer brake hydraulic control Hydraulic schema (view of Italian trailer brake assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Trailer brake valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove (Italian Trailer Brake Solenoids Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

DIAGNOSTIC Trailer brake valve Troubleshooting (Italian trailer brake.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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Brakes and controls - Trailer brake hydraulic control

Trailer brake hydraulic control - General specification Maximum Trailer Brake Pressure Italian trailer brake Trailer brake disengagement pressure

150 bar (2175.0 psi) 10 - 12 bar (145.00 - 174.00 psi)

Trailer brake hydraulic control - Special tools CAUTION The operations described in this section can only be carried out with the ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. B008

Pressure Test Tools Tool No.

X X X

380000543 380000545 380000550 380000552 380000553

Description Quick release coupler Hose Pressure gauge connection Pressure Gauge 0 - 40 bar (0 - 580 psi) Pressure Gauge 0 - 250 bar (0 - 3625 psi)

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Alternative previous No. 291924 292246 293242 293244

Brakes and controls - Trailer brake hydraulic control

Trailer brake hydraulic control - Hydraulic schema (view of Italian trailer brake assembly)

WLAPL4S35C401G

: Oil from the pump. : Oil to discharge. : Oil at trailer braking pressure. : Oil at service brake pedal braking pressure.

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Brakes and controls - Trailer brake hydraulic control

Layout of Italian trailer braking components. (P) - Oil coming from the pump at the inlet of the base of the spool valve turret / EDC . (P1) - Oil, not used by the trailer brake valve, destined for the other high pressure circuit services. (R) - Oil at the outlet from the trailer mechanical brakes release pressure regulating valve. (R1) - Oil at the outlet from the normally closed solenoid valve if either the parking brake is applied or there is not enough pressure from the pump. (Y) - Oil at the outlet, blow-by inside the trailer brake valve. (B) - Oil at the trailer braking pressure from the trailer braking valve to the spool valve, Italian version. (B1) - Oil at the trailer braking pressure from the spool valve, Italian version, to the trailer brake quick coupler. (X1) - Oil at the braking pressure from the left brake pedal. (X2) - Oil at the braking pressure from the right brake pedal. (1) . - Spool valve for Italian version trailer brake circuit application. (2) . - Trailer brake valve rear surface. (3) . - Circuit safety pressure switch, calibrated to 3 bar (43.50 psi) ( 3,06 Kg/cm2) . (4) . - Solenoid valve normally open, Italian hand brake circuit. (5) . - Solenoid valve normally closed, Italian hand brake circuit. (6) . - Trailer brake valve. (7) . Trailer release oil outlet fitting (R1) . (8) . - Trailer mechanical braking release pressure switch, calibrated to 10 bar (145.00 psi) (10,19 Kg/cm2) . (9) . - Oil line, under trailer braking pressure, from the valve to the spool valve. (10) . - Oil line, under trailer braking pressure, from the spool valve to the quick coupler. (11) . - Trailer mechanical braking release pressure regulating valve, calibrated to 10.9 - 11.6 bar (158.05 168.20 psi) (11,11 รท 11,82 Kg/cm2) . (12) . - Trailer mechanical brake.

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WLAPL4S35C401B

Brakes and controls - Trailer brake hydraulic control

Trailer brake hydraulic control - Dynamic description Trailer brakes off With the trailer brakes off, the oil from the hydrostatic circuit connected to the control valve by union (Y) is not pressurized and therefore the piston (5) of the pilot valve (6) and the spool (7) are in the rest positions indicated in figure. The oil from the hydraulic pump flows to port (P1) and passes through the diaphragm (1) and restriction (3) where there is a drop in pressure, pushing the flow control valve (2) to the right. The majority of the oil flows through the port (N) to the auxiliary control valves, while the rest of the oil is discharged to the hydraulic lift through the line (4), slide piston (7) and port (R). : Pressurised oil : Oil in suction, delivery or return : Oil at static rest : Tractor brake circuit oil at rest : Pressurized tractor brake circuit oil

SEZ35CAP4A-2

Trailer brakes off (N). To the auxiliary control valves. (P1). From the hydraulic pump to the lift circuit. (R). To the return line in the lift. (Y). From the tractor brakes.

START OF BRAKING When the tractor brake pedals are pressed, the hydrostatic circuit oil enters union (y) under pressure, moving the piston (7), pressure limiter (6) and spool (8) to the left. This interrupts the communication with the oil discharge union (R), trailer brake union (B) and line (5). The oil inside the flow control valve (4) is maintained at a uniform pressure, allowing the valve element, under the action of the spring, shifts to the left to assume the position indicated in the drawing. Part of the oil from the hydraulic pump in port (P1), flows to the auxiliary control valves through port (N), while the remaining part arrives at the tractor braking element via the diaphragm (2), line (3), check valve (1) and port (B). As the pressure of the oil in the trailer brake port (B) increases, it acts on the active surface (9) of the spool (8), opposing the pressure applied on piston (7) by the oil in the hydrostatic tractor brake circuit.

: : : :

SEZ35CAP4A-3

Start of braking (B). To the trailer brake. (N). To the auxiliary control valves. (P1). From the hydraulic pump to the lift circuit. (R). To the return line in the lift. (Y). From the tractor brakes.

Pressurised oil Oil in suction, delivery or return Oil at static rest Pressurized tractor brake circuit oil

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Brakes and controls - Trailer brake hydraulic control

BRAKING If the driver continues to operate the tractor brake pedals, the pressure of the oil in the trailer brake port (B) increases and acts on the active surface (10) of the slide piston (9), and overcomes the resistance of the pressure limiter (8) springs (7), to shift the slide piston (9) to the right. When the pressure in the trailer brake circuit balances the pressure exerted by the springs (7), the spool (9) stabilizes in the position indicated in figure opening the gallery connecting the oil from the pump with the hydraulic lift return line through port (P1), the diaphragm (2), restriction (5), line (6) and the port (R). The diaphragm (2) and the constriction (5) cause a drop in the pressure of the oil circulating in the flow control valve (4), thus shifting the valve element to the right to close gallery (3) and consequently the check valve (1). Further pressure on the tractor brake pedals shifts the piston (7), the pressure limiter (8) and the slide piston (9) to the left, thus causing an increase in the trailer brake circuit pressure, repeating the stages described in the paragraph "START OF BRAKING". If the pressure in the trailer brake circuit increases as a result of external causes, the spool (9) shifts rapidly to open the gallery connecting the trailer brake port (B) and the lift return port (R), thus maintaining a perfect balance between the oil pressure in the braking circuit and the force exerted by the pressure limiter springs (7). On releasing the tractor brake pedals, the pressure in port (y) drops and the conditions illustrated in 1 are restored.

SEZ35CAP4A-4

Braking (B). To the trailer brake. (P1). From the hydraulic pump to the lift circuit. (R). To the return line in the lift. (Y). From the tractor brakes.

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Brakes and controls - Trailer brake hydraulic control

ELECTRO-HYDRAULIC OPERATION OF TRAILER BRAKE VALVE ( ITALIA VERSION ) Engine running - no action on brake pedals

WLAPL4S35C402G

: : : :

Oil in suction or delivery Discharge oil Tractor brake circuit oil at rest Oil at trailer brake release pressure

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Brakes and controls - Trailer brake hydraulic control

(1). Parking brake control lever

(12). Auxiliary control valve and hydraulic lift supply piping (2). Parking brake indicator circuit relay (13). Service brake pump (3). Trailer brake circuit relay (14). Tractor-trailer coupling (4). Trailer braking control solenoid valves (15). Trailer brake control piping (5a). Delivery solenoid valve (normally open) (16). Trailer brake on indicator switch (5b). Discharge solenoid valve (normally closed) (17). Spring (6). Trailer brake release pressure control valve (19). Spring (7). Trailer braking valve (see "TRAILER BRAKES OFF") (18). Trailer brake control pin (8). Trailer brake circuit safety switch (20). Battery (9). Hydraulic pump (21). Parking brake switch (10). Filter (22). Trailer brake indicator lamp (11). Main brake control piping Oil from the hydraulic pump (9) arrives at the trailer brake valve (7), from where the majority is sent through line (12), to the auxiliary control valves and the hydraulic lift. A small amount of oil reaches valve (6), where it is discharged in order to maintain the pressure at a level of 11 - 12 bar (159.50 - 174.00 psi). Oil at a pressure of 10.9 - 11.6 bar (158.05 - 168.20 psi) flows from the trailer brake valve through solenoid valve (5a), line (15) and coupling (14) to arrive at the trailer brakes. This pressure level is required to overcome the resistance of the spring (19) and move the relative spring cap. At the same time, spring (17) shifts the piston (18) to prevent any braking action on the trailer. ATTENTION: On starting the engine, in order to reduce the length of time required to bring the circuit up to the pressure required to release the trailer brake, with the parking brake lever lowered, operate the brake pedals (make sure that they are linked together). Once the trailer brake is released the warning light (22) will be switched off.

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Brakes and controls - Trailer brake hydraulic control

ELECTRO-HYDRAULIC OPERATION OF TRAILER BRAKE VALVE ( ITALIA VERSION ) Engine running - brake pedals pressed

WLAPL4S35C403G

: : : :

Oil in suction or delivery Discharge oil Pressurized tractor brake circuit oil Oil at tractor brake release pressure

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Brakes and controls - Trailer brake hydraulic control

(A). Line connecting brake pump (13) to trailer brake valve (7) (1). Parking brake control lever

(11). Main brake control piping

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Brakes and controls - Trailer brake hydraulic control

ELECTRO-HYDRAULIC OPERATION OF TRAILER BRAKE VALVE ( ITALIA VERSION ) Engine either stopped or running but with insufficient flow from hydraulic pump

WLAPL4S35C404G

: Oil in suction or delivery : Discharge oil : Tractor brake circuit oil at rest

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Brakes and controls - Trailer brake hydraulic control

(1). Parking brake control lever

(12). Auxiliary control valve and hydraulic lift supply piping (2). Parking brake indicator circuit relay (13). Service brake pump (3). Trailer brake circuit relay (14). Tractor-trailer coupling (4). Trailer braking control solenoid valves (15). Trailer brake control piping (5a). Delivery solenoid valve (normally open) (16). Trailer brake on indicator switch (5b). Discharge solenoid valve (normally closed) (17). Spring (6). Trailer brake release pressure control valve (19). Spring (7). Trailer braking valve (see "TRAILER BRAKES OFF") (18). Trailer brake control pin (8). Trailer brake circuit safety switch (20). Battery (9). Hydraulic pump (21). Parking brake switch (10). Filter (22). Trailer brake indicator lamp (11). Main brake control piping When the engine is stopped, or running but with insufficient flow from the hydraulic pump (9), the oil pressure at the trailer brake valve (7) is either too low or non-existent, and this condition causes the safety switch to close (8). The closure of switch (8) allows electrical current to energize relay (3), which closes the circuit to the solenoid valves ( (5a) and (5b)), thereby closing the former and opening the latter. In this condition, the oil in the trailer brake and line (15), under the action of spring (19), is discharged through solenoid valve (5b), and the braking action is obtained mechanically by the pressure of spring (19) on pin (18). The pressure drop caused by the oil discharging allows switch (16) to close and thereby allow current to reach and illuminate warning light (22) on the control panel.

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Brakes and controls - Trailer brake hydraulic control

ELECTRO-HYDRAULIC OPERATION OF TRAILER BRAKE VALVE ( ITALIA VERSION ) Engine running - with parking brake on

WLAPL4S35C405G

: Oil in suction or delivery : Discharge oil : Tractor brake circuit oil at rest

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Brakes and controls - Trailer brake hydraulic control

(1). Parking brake control lever

(12). Auxiliary control valve and hydraulic lift supply piping (2). Parking brake indicator circuit relay (13). Service brake pump (3). Trailer brake circuit relay (14). Tractor-trailer coupling (4). Trailer braking control solenoid valves (15). Trailer brake control piping (5a). Delivery solenoid valve (normally open) (16). Trailer brake on indicator switch (5b). Discharge solenoid valve (normally closed) (17). Spring (6). Trailer brake release pressure control valve (18). Trailer brake control pin (7). Trailer braking valve (see "TRAILER BRAKES OFF") (19). Spring (8). Trailer brake circuit safety switch (20). Battery (9). Hydraulic pump (21). Parking brake switch (10). Filter (22). Trailer brake indicator lamp (11). Main brake control piping Turning on the starter switch (23) delivers current to the relay coil (24) energizing it. Operating the parking brake turns on the magnetic switch (21), the current flowing through the switch reaches the relay coil (2) energizing it. This enables the current to get to energize the solenoid valves ( (5a) and (5B)), thereby closing the former and opening the latter. In this condition, the oil in the trailer brake and line (15), under the action of spring (19), is discharged through solenoid valve (5b), and the braking action is obtained mechanically by the pressure of spring (19) on pin (18). The pressure drop caused by the oil discharging allows switch (16) to close and thereby allow current to reach and illuminate warning light (22) on the control panel. ATTENTION: After applying the parking brake, wait approximately 10 s before shutting off the engine, in order to allow all the oil to be discharged from the trailer brake cylinder and thus obtaining optimum braking.

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Brakes and controls - Trailer brake hydraulic control

Trailer brake valve - Remove 1.

Disconnect the trailer brake valve electrical connectors and reposition the wiring harness. Disconnect the trailer brake valve oil supply pipe (1)

BVE0455A

BVE0456A

BVE0457A_472

Disconnect the brake pipes (1) and (2) from the trailer brake valve.

Remove the trailer brake valve retaining bolt.

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Brakes and controls - Trailer brake hydraulic control

Remove the remaining trailer brake valve retaining bolts and remove the trailer brake valve.

BVE0458A_473

Next operation: Trailer brake valve - Install (33.220)

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Brakes and controls - Trailer brake hydraulic control

Trailer brake valve - Install Prior operation: Trailer brake valve - Remove (33.220) NOTE: If required, install new O-rings. 1.

Install the trailer brake valve and the trailer brake valve retaining bolts.

BVE0458A_473

BVE0457A_472

NOTE: If required, install new O-rings. 2.

Install the trailer brake valve and the trailer brake valve retaining bolts.

Install the remaining trailer brake valve retaining bolt.

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Brakes and controls - Trailer brake hydraulic control

Connect the brake pipes (1) and (2) to the trailer brake valve.

BVE0456A_474

BVE0455A

Connect the trailer brake valve oil supply pipe (1). Connect the trailer brake valve electrical connectors.

Next operation: Bleed the brake system - refer to Hydraulic service brakes - Bleed (33.202). Top up the transmission with oil of the correct specification - refer to Powered rear axle - General specification (27.100).

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Brakes and controls - Trailer brake hydraulic control

Trailer brake valve - Remove (Italian Trailer Brake Solenoids Block) 1.

Disconnect the trailer brake solenoid valve block electrical connectors.

Disconnect the trailer brake valve oil supply pipe (1)

BVE0455A

BVE0459A

Disconnect the oil supply tube (1) from the quick coupling and remove the banjo bolt (2) from the Italian trailer brake solenoid valve block.

Remove the Italian trailer brake solenoid valve block with the oil supply pipes attached.

Remove the oil supply pipes from the Italian trailer brake solenoid valve block.

Next operation: Trailer brake valve - Install (33.220)

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Brakes and controls - Trailer brake hydraulic control

Trailer brake valve - Pressure test Oil temperature 40 - 50 Â°C (104 - 122 Â°F). Engine speed 1000 RPM. Electrical system powered. Parking brake disengaged.

TRAILER BRAKE SYSTEM PRESSURE TEST 1.

Insert fitting no. 380000550 (1) in the trailer brake coupling and connect it to a pressure gauge with scale 0 - 250 bar (0 - 3625 psi) 380000553, using the quick coupling 380000543 and the flexible pipe 380000545.

Connect the brake pedals together and, with the engine and the oil at the conditions stated at the start of this chapter, depress the brake pedals. The reading on the pressure gauge should increase according to the force on the pedal, up to a value of between 135 - 145 bar (1958 - 2103 psi).

If it does not read a pressure of 135 - 145 bar (1958 2103 psi), check the system as described in Trailer brake valve - Troubleshooting (33.220).

Apply the parking brake, disconnect the pressure gauge and union no. 380000550 (1).

BVE0169A

TRAIL BRAKE SYSTEM LEAK TEST 5.

Connect the brake pedals together and, with the engine and the oil at the conditions stated at the start of this chapter, depress the brake pedals for at least 10 seconds. The reading on the pressure gauge should increase to between 135 - 145 bar (1958 - 2103 psi) and remain constant. 47538922 29/05/2013

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Brakes and controls - Trailer brake hydraulic control

If it does not read a pressure of 135 - 145 bar (1958 2103 psi), check the system as described in Trailer brake valve - Troubleshooting (33.220).

Apply the parking brake, disconnect the pressure gauge and union no. 380000550 (1).

TRAILER BRAKE DISENGAGEMENT PRESSURE TEST (ITALIAN VERSION ONLY) 9.

Insert fitting no. 380000550 (1) in the trailer brake coupling and connect it to a pressure gauge with scale 0 - 40 bar (0 - 580 psi) 380000552, using the quick coupling 380000543 and the flexible pipe 380000545.

10.

With the engine and the oil in the above-mentioned conditions, the pressure must be 11 - 12 bar (160 174 psi).

11.

Ensure that the indicator light is switched OFF.

12.

If it does not read a pressure of 11 - 12 bar (160 174 psi), check the system as described in Trailer brake valve - Troubleshooting (33.220).

13.

Apply the parking brake, disconnect the pressure gauge and union no. 380000550 (1).

BVE0169A

PARKING BRAKE ENGAGEMENT TEST (ITALIAN TRAILER BRAKES ONLY) 14.

15.

With the engine and the oil at the conditions stated at the start of this chapter, pull the parking brake control lever fully.

16.

Check that the pressure is at 0 bar (0 psi) and that the indicator light is ON.

17.

If it does not read a pressure of 0 bar (0 psi), check the system as described in Trailer brake valve Troubleshooting (33.220). 47538922 29/05/2013

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Brakes and controls - Trailer brake hydraulic control

18.

With the parking brake engaged, disconnect the pressure gauge and the fitting no. 380000550 (1).

TRAILER BRAKE CIRCUIT SAFETY SWITCH TEST (ITALIAN TRAILER BRAKES ONLY) 19.

BVE0169A

20.

With the parking brake OFF and tractor brakes not applied, operate and hold the remote control valve lever and allow the system pressure relief valve to operate. Keep this position for a few seconds and quickly release the control lever.

21.

Check that the parking brake release pressure remains at the prescribed level of 11 - 12 bar (160 174 psi).

22.

If it does not read a pressure of 11 - 12 bar (160 174 psi), check the system as described in Trailer brake valve - Troubleshooting (33.220).

23.

Apply the parking brake, disconnect the pressure gauge and union no. 380000550 (1).

HYDRAULIC TRAILER BRAKE TEST (ITALIAN VERSION)

Starter keyswitch to “ON” Engine running (at 800 1000 RPM)* Engine running (at 800 1000 RPM)* Engine running (at 800 1000 RPM)* Engine running (at 800 1000 RPM)* Engine running (at 800 1000 RPM)* Engine running (at 800 1000 RPM)* Engine running (at 800 1000 RPM)* Engine running (at 800 1000 RPM)*

Service brake

Handbrake RELEASED

Indicator light (trailer brakes) ON

Pressure gauge pressure at the coupling 0 bar (0 psi)

RELEASED RELEASED

RELEASED

OFF*

10 bar (145 psi)

RELEASED

ENGAGED

0 bar (0 psi)

RELEASED

OFF

10 bar (145 psi)

Progressively engage the brake pedal

RELEASED

OFF

10 bar (145 psi)- 120 bar (1740 psi)/ 150 bar (2175 psi)

ENGAGED

0 bar (0 psi)

ENGAGED

RELEASED

OFF

120 bar (1740 psi)/ 150 bar (2175 psi)

Progressively release the brake pedal

RELEASED

OFF

120 bar (1740 psi)/ 150 bar (2175 psi) - 10 bar (145 psi)

RELEASED

ENGAGED

0 bar (0 psi)

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Brakes and controls - Trailer brake hydraulic control

Engine running (at 800 1000 RPM)* Starter keyswitch to "OFF"

Service brake

Handbrake

Indicator light (trailer brakes)

Pressure gauge pressure at the coupling

RELEASED

OFF

10 bar (145 psi)

RELEASED

OFF

0 bar (0 psi)

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Brakes and controls - Trailer brake hydraulic control

Trailer brake valve - Troubleshooting (Italian trailer brake.) Problem Trailer brake valve - Low pressure (33.220.AM-G.10.K.16) Trailer brake valve - False alarms (33.220.AM-G.10.H.10) Trailer brake valve - Alarm light (33.220.AM-G.10.H.20) Trailer brake valve - Not engage (33.220.AM-G.10.B.14) Trailer brake valve - Not disengage (33.220.AM-G.10.B.30)

Possible Cause

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Correction

Index Brakes and controls - 33 Trailer brake hydraulic control - 220 Trailer brake hydraulic control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Trailer brake hydraulic control - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Trailer brake hydraulic control - Hydraulic schema (view of Italian trailer brake assembly) . . . . . . . . . . . . . . . . . . . . 4 Trailer brake hydraulic control - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Trailer brake valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Trailer brake valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Trailer brake valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Trailer brake valve - Remove (Italian Trailer Brake Solenoids Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Trailer brake valve - Troubleshooting (Italian trailer brake.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47538922 29/05/2013 EN

SERVICE MANUAL Hydraulic systems

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[35.322] Regulated/Low pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[35.114] Three-point hitch control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

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Hydraulic systems - 35 Hydraulic systems - 000

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Static description The hydraulic systems can be separated into the following circuits:

High pressure circuit Fixed displacement pump 80 l/min (21.1 US gpm) • Closed centre electronic hydraulic lift assembly. • Closed centre Bosch remote valves. • Trailer brakes (where fitted). • Closed centre mid-mount remote valves. • Closed centre electro-hydraulic mid-mount remote valves. • Front lift (where fitted). Fixed displacement pump 63 l/min (16.6 US gpm) • Closed centre electronic hydraulic lift assembly. • Closed centre Bosch remote valves. • Trailer brakes (where fitted). • Open centre mid-mount remote valves.

Steering Circuit • Steering Circuit.

Low pressure circuit • Independent power take−off (PdF). • Differential lock. • Four-wheel drive engagement. • Transmission clutch and synchroniser coupling. • Creeper engagement (where fitted) • PdF front (where fitted). • Front axle braking. • Pilot line for mid-mount remote valve with electrohydraulic control. • Diverter valve pilot line.

Lubrication Circuit • Clutch plates PdF. • Transmission Clutch Plates. • Drive shaft lubrication. • Differential lubrication. • Hydraulic lift rocker shaft.

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Hydraulic systems - Hydraulic systems

High pressure circuit - Fixed displacement pump Lift pump 1. High Pressure Pump 2. Filter 3. Pump intake 4. Oil suction from transmission 5. Pump supply 6. Pressure regulating valve 190 - 195 bar (2755 - 2828 psi)

MOIL13TR00252AA

MOIL13TR00276AA

MOIL13TR00277AA

MOIL13TR00278AA

â&#x20AC;˘ The oil passes through the pipe (3), reaches the righthand side of the base (1) of the remote valve stack, where the pressure port (2)supplying oil to the remote valves is also located.

â&#x20AC;˘ On the left-hand side of the base of the valve stack (1) there is a pressure regulating valve (2) that is calibrated to 210 bar (3045 psi). Internally there is a flow control valve that is piloted by the load sensing line. The line comes from the supplementary remote valves, from the electronic lift control inside the valve stack and from the mid-mount remote valves via an external pipe. If there is a demand for oil from these actuators, oil will be sent from the flow control valve. Otherwise the oil will return directly to tank.

â&#x20AC;˘ On the front of the tower, and directly coupled the trailer brake valve (1), driven by the logic valve and from both the rear brake lines. In particular this machine is fitted with the remote valve (2) of the Italy version. On the rear the hydraulic trailer brake quick (3) coupling.

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Hydraulic systems - Hydraulic systems

• Above the base the electronic lift remote valve (1) with the two lifting (3) and lowering (2) solenoid valves. The oil travels from the pipe (4) to the main cylinder and also, where installed, to the supplementary cylinders.

MOIL13TR00279AA

MOIL13TR00280AA

MOIL13TR00281AA

MOIL13TR00282AA

• Above the lift remote valve there is a package of 2 to 3 additional Bosch remote valves, with flow control (2) and lever retainer (detent), programmable (1) or otherwise (3).

• On the third remote valve it is possible to mount a splitter (1) which uses the remote valve for two specific functions on two different implements. The flow splitter is controlled by a solenoid valve (2) that opens a passage (3)allowing low pressure oil to flow. The oil moves a spool that diverts the high pressure oil flow to the two output ports of the of the splitter. Pipe (4) is connected to the return line. When the solenoid valve is not energised, a spring, located on the opposite side to the low pressure oil inlet, shifts the spool so the oil in the upper chamber can return to tank.

• There is a cover (1) on the tower where, through the pipe (2), the oil is sent from the load sensing line to the mid-mount remote valves.

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Hydraulic systems - Hydraulic systems

â&#x20AC;˘ On the right hand side of the machine under the cab there is a mid-mount remote valve (1) controlled by a mechanical joystick in the cab. The remote receives oil from the flow control valve at the base of the stack through line (2) and the load sensing line (3). The oil returns to tank through the pipe (4) on the right-hand side of the lift cover.

MOIL13TR00283AA

â&#x20AC;˘ Another type of mid-mount remote valve is electro-hydraulic (1), which is controlled by an electronic joystick. Supplied through the pipe (2), through the load sensing line (4) the remote valve requests oil from the flow regulating valve at the base of the tower and the oil runs through the pipe (3) to the outlet. Otherwise, from the mechanical remote valve the spools operating the two remote valves are controlled by the low pressure oil through the pipes (5).

MOIL13TR00284AA

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Hydraulic systems - Hydraulic systems

Steering Circuit • The steering circuit is supplied with oil by the pump (1), mounted in tandem with the high pressure pump, which draws oil from the pipe (2) and sends it under pressure through pipe (3) to the anti-cavitation tank (4), and then to the pipe fitting (5).

MOIL13TR01211AB

MOIL13TR01215AB

MOIL13TR00292AA

MOIL13TR00293AA

• From the pipe fitting, the oil takes two separate paths. One of these paths is through the hexagonal fitting (1). Inside the fitting there is a filter. From the filter, the oil flows into a block housing the protection valve (3) for the power steering pump, set to 205 - 210 bar (2972 3045 psi). This valve intervenes in cold climatic conditions when the oil is very dense. It opens to discharge excessive pressure in order to prevent damage to the power steering pump. The oil is discharged via the pipe (2) and returns to the gearbox control valve, joining the flow from the oil cooler.

• the other path, through the pipe (1), sends the oil to the power steering control valve (2). The oil is returned to tank through the pipe (3). The pipes (4) are for the right and left steering.

Low pressure circuit • The return oil from the power steering control valve flows through the pipe (1) to the filter on the low pressure circuit (2), and then flows through the pipe (3) to the gearbox control valve.

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• The oil from the filter flows through the pipe (2) to the gearbox control valve. The oil flows through the pipe (1) to the services control valve and, at the same time, flows to the accumulator (3) via the pipe (4).

MOIL13TR01212AB

MOIL13TR00259AA

MOIL13TR00260AA

MOIL13TR00261AA

• The oil proceeds through pipe (4) to the services control valve (3) and passes through a hub including the pipe (1) which carries oil to the front axle brakes, and through the pipe (2) to pilot the splitter spool (if fitted).

NOTE: In the variant with electro-hydraulic mid-mount remote valves (1), the pipes (2) carrying the oil flow used to pilot the actuators of the two remote valves come from the accumulator (3) and from the transmission cover.

• The oil flows through the pipe (2) to the head (1) of the services control valve. This houses a valve controlling the transmission and services pressure calibrated to 17 bar (246 psi) to 18 bar (261 psi). The excess oil goes to the oil cooler bypass valve, which is calibrated to 5.8 bar (84.1 psi) ± 0.5 bar (7.2 psi); if the oil is cold, the bypass valve opens, if the oil is hot it flows through the pipe (3) to the oil cooler

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• the pipe (3) goes to the oil cooler (1), the return flow goes to the transmission control valve through the pipe (2)

MOIL13TR00263AA

MOIL13TR01213AB

MOIL13TR00262AA

• through the pipe (2) it enters the transmission control valve (1), and exits through the pipe (3)

• the pipe (3) returns to the head of the services control valve (1), meets the lubrication pressure regulating valve calibrated to 7.8 bar (113.1 psi) ± 0.5 bar (7.2 psi), having lubricated the differential through the pipe (4) and the power take-off through the pipe (2).

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Services control valve At the base of the services control valve are located the solenoid valves controlling engagement of the: 2. Creeper 3. Differential lock 4. Power take off clutch 5. Four-wheel drive 6. PTO brake The sensor (7) is a pressure switch that tests the service coupling oil pressure. The pipe (1) and the front differential locking pipe. MOIL13TR00265AA

MOIL13TR00266AA

MOIL13TR00267AA

MOIL13TR00269AA

There are other pipes inside the rear transmission housing: 1. PTO brake 2. Rear differential lock 3. Four-wheel drive 4. Power take off clutch 5. Creeper 6. Exhaust

transmission control valve In the lower part, the four clutch solenoid valves: 1. C1 clutch 2. C2 clutch 3. C3 clutch 4. C4 clutch Through the pipe (3) and connected to the services control valve where the valve is. The temperature sensor (6).

In the inner part, the lubrication and clutch supply pipes: 1. Clutch C2 supply 2. Clutch C1/ C2 lubrication supply 3. Clutch C3 supply 4. Clutch C3/ C4 lubrication supply 5. Clutch C4 supply 6. Clutch C1 supply 7. Bearing/synchroniser lubrication pressure

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• Again in the inner part the lubrication assembly (1) where we find the lubrication valve, calibrated max. to 7 bar (102 psi)

MOIL13TR00268AA

MOIL13TR00271AA

MOIL13TR00275AA

MOIL13TR01214AB

• From the transmission side remote valve (1) to the upper remote valve (2) the low pressure oil pipe is the (3).

On the upper cover (1) we find: 2. 5-8 range PWM valve 3. 1-4 range PWM valve 4. 1-4 / 5-8 range synchroniser reading potentiometer 5. Shuttle synchroniser reading potentiometer 6. Reverse gear PWM valve 7. Forward gear PWM valve The two ranges (1-4 and 5-8) and the shuttle are selected mechanically with electro-hydraulic couplings.

Front axle braking • On the pipe (4) that connects the pressure line filter to the end plate of the services control valve, there is a pipe (3) that takes the low pressure oil to the front brakes. On the upper part of the transmission are the rear axle braking pipes (1) the front axle braking remote valve piloting (5) and the front axle braking oil outlet pipe (2).

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â&#x20AC;˘ On the right hand side under the cab is the front braking remote valve (1), with the low pressure oil pipe (4) to the front brake (2), the piloting from the logic valve (3), the low pressure outlet pipe and the low pressure oil supply (5).

MOIL13TR00272AA

MOIL13TR00274AA

MOIL13TR00273AA

â&#x20AC;˘ The logic valve (1) is fitted on the trailer valve, piloted by the left brake pipe (2), right brake pipe (3) and the outlet (4) to the front braking remote valve pilot.

â&#x20AC;˘ In the version with the mid-mount remote valve, the logic valve (1) is on the front right-hand side of the remote valve stack. This is also piloted by the left brake pipe (2), right brake pipe (3) and the outlet (4) to the front braking remote valve pilot.

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Hydraulic systems - Hydraulic schema Tractors with 16 X16 – 32 X 32 transmission (with creeper) with front axle braking, trailer brake valve, electronic lift, Bosch supplementary remote valve, and closed centre mechanical and electronic ventral control valve supplied with a fixed delivery pump and front power take-off. A. Control valve tower for closed centre with double acting and floating function with flow rate adjuster and automatic release on request, also programmable.

B. EDC control valve assy (Electronic lift).

C. Tower base

D. Trailer brake quick coupler. E. Trailer brake control valve for Italy market.

F. Trailer. G. Trailer brake valve.

H. Services control valve.

I. Services control valve head.

1. Tower head with one-way valve and hitch for pilot, ventral control valves, flow control valve. 2. Control valve assy. 3. Flow-rate regulator. 4. Automatic release. 5. Flow compensator valve. 6. Lower solenoid valve. 7. Raise solenoid valve. 8. Cylinder safety valve (cuts in if the cylinder pressure increases excessively due for example to jolting of the tool hitched to the lift). Calibrated to 250 bar (3625.0 psi). 9. Flow control valve. 10. High pressure circuit limit valve, a second one is mounted on the suction filter cover (46). Calibrated to 200 bar (2900 psi). 11. Trailer brake quick coupler for Italy market. 12. Normally open solenoid valve. 13. Solenoid valve normally closed. 14. Pressure switch calibrated to 10 bar (145 psi) ± 0.5 bar (7.2 psi). 15. Automatic mechanical parking braking device. 16. Check valve (Italy market only), in the previous circuit maintains a pressure of 10.9 - 11.6 bar (158 - 168 psi). 17. Trailer brake valve spool. 18. Flow-rate regulator. 19. Pressure switch calibrated to 3 bar (44 psi) ± 0.5 bar (7.2 psi). 20. Logic valve, only when oil reaches the two ports X1 and X2 from the two right and left brake pumps, at the same pressure it sends oil to the trailer brake valve spool pilot and to the front axle brake control valve, if equipped. 21. Front-wheel drive decoupling solenoid valve. 22. PTO brake solenoid valve. 23. Creeper coupling solenoid valve. 24. Front and rear differential lock engagement solenoid valve, if equipped. 25. PTO engagement solenoid valve. 26. Pressure sensor, measures the pressure in the low pressure circuit. 27. Lubrication pressure control valve (there is a second one on the transmission control valve). Calibrated to 7.8 bar (113.1 psi) ± 0.5 bar (7.2 psi) .

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28. Heat exchanger protection valve, opens only in the presence of cold, dense oil to prevent damage to the exchanger. In the presence of hot fluid oil, with lower pressure, it remains closed and sends the oil to the exchanger. Calibrated to 5.8 bar (84.1 psi) ± 0.5 bar (7.2 psi). 29. Low pressure regulating valve. Calibrated to 17 - 18 bar (246 - 261 psi). 30. Control valve spool hydraulic head. 31. Control valve spool logic valve. 32. Front PTO engagement solenoid valve. 33. Low pressure oil temperature sensor. 34. Lubrication pressure control valve, another is fitted on the services control valve head. Calibrated to 7 bar (102 psi). 35. Combined lubrication valve. 36. Lubrication selector valve. 37. Clutch engagement PWM valves. 38. Clutches. 39. Shaft lubrication circuit, inside the casing, and differential lubrication, outside the transmission casing.

J. Heat exchanger. K. Front axle braking spool valve. L. Front axle with locking and braking. M. Front PTO. No. Gearbox control valve.

O. Accumulator. This reduces the pressure in the gear changes quickly. Charged at 10 bar (145 psi), capacity 0,7 l. P. Upper transmission control valve.

Q. Power steering motor (orbitrol). /I. Pressure filter.

S. Power steering motor protection valve. In cold temperature, with very dense oil and thus high pressure, this valve opens and drains the pressure to prevent damage to the motor. Calibrated to a pressure of 205 - 210 bar (2972 - 3045 psi). T. Filter. The filter is located just before the control valve where the (S) valve is mounted, inside a hexagonal fitting. U. Reservoir. This small reservoir is a resonance damper. V. Relief valve filter, pump assembly.

40. Shuttle synchro engagement solenoid valves, F (forward) and R (reverse) and range synchroniser, A (1 4) and B (5 - 8). 41. Synchroniser engagement fork handling double acting hydraulic pistons. 42. Circuit relief valve. Calibrated to 170 bar (2465 psi) 43. By-pass valve, if the filter is blocked, when the difference between the inlet oil pressure to the filter and the outlet pressure is slightly higher than the valve calibration the valve opens and sends oil, even if not filtered, to the devices beyond the filter. Calibrated to 3.5 bar (50.8 psi) ± 0.3 bar (4.4 psi).

44. Suction pump for high pressure system. Pump flow rate approx. 25 cm³/rev or 32 cm³/rev. NOTE: In the circuit with EHRs there is only the pump with flow rate 32 cm³/rev.

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45. Low pressure and power steering motor suction pump, flow rate 16 cmÂł/rev. 46. Suction filter . 47. High pressure circuit relief valve, a second one is located at the base of the control valve tower (C). Calibrated to 190 - 195 bar (2755 - 2828 psi). 48. By-pass valve, prevents the systems from running with no oil. When the pressure difference between the oil before the filter and after the filter exceeds the valve calibration, the valve opens and the oil passes even if it is not filtered. Calibrated to 0.8 bar (11.6 psi). W. Service brakes. Brake assy, right and left pump. X. Rear transmission. Here is the rear differential lock, the differential assy, rear brakes, four-wheel drive engagement and creeper (not represented here). Y. Rear PTO and brake. 49. Lubrication flow reduction valve. The valve spool is piloted by the PTO clutch packing pressure. The solenoid valve is modulated and during modulation at low pressure the lubrication oil flow is heavy, until almost peak pressure which counteracts the spring thus reducing the lubrication flow. 50. Lubrication start valve. This is also piloted by the low pressure circuit. During modulation, the spring, which normally reduces the flow, opens with minimum pressure and stays open. Z. Ventral control valve. 51. Double-acting auxiliary control valve with float. 52. Double-acting control valve. Z1. EHR. 51. Double-acting auxiliary control valve with float. The spool is driven by the low pressure oil through two solenoid valves. 52. Flow control. Key to circuits. a. Oil suction from rear transmission through the filter to the pumps. Low pressure power steering and lubrication. b. Oil pump delivery line (44), through the tank (U), the filter (T) and the valve (S) to the power steering motor (Q). c. Oil discharging from the valve (S) that does not go to the rear transmission but reaches the low pressure oil (D) near the transmission control valve (M). d. Oil discharged from the power steering motor, through the filter (R) it reaches the services control valve head (I) pressing the valve (29) to control the whole circuit at a pressure of 17 - 18 bar (246 - 261 psi) and works on: - services operation, control valve (H) - clutch packing, control valve (N) - double acting piston engagement on synchronisers, shuttle and ranges 1 - 4 and 5 - 8, control valve (P) - front power take-off engagement, assy (M) - EHR spool piloting, control valves (Z1) - front axle braking, control valve (K) e. Circuit oil (d) discharged from the valve (29), due to the high temperature does not open the by-pass valve (28) protecting the exchanger. It reaches the exchanger, cools down, and returns to the transmission control valve (N). f. Circuit oil (e) in the transmission control valve (N) on a first valve (34) which controls the circuit at 7 bar (102 psi), covers all the lubrication circuit and ends on the services control valve head (I), where a second valve (27) controls the circuit at 7.8 bar (113.1 psi) Âą 0.5 bar (7.2 psi). On the transmission control valve, via internal pipes, at a variable flow controlled by the valve (35), lubricates the 4 clutches and also internally the transmission shafts. Leaving the transmission control valve, it returns to the services control valve head, during the journey it lubricates the rear differential and, also in this case with a variable flow controlled by the valve (49) and (50), the rear power take-off assy (Y).

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g. Oil from the differential lock solenoid valve (24), inside the casing engages with the rear assy. Externally, it engages with the front assy. h. Oil from the PTO brake solenoid valve (22) internally engages the brake. l. Oil from the four-wheel drive solenoid valve (21) internally disengages the drive. m. Oil from the PTO solenoid valve (25) internally engages the brake and drives the lubrication valves (49) and (50). High Pressure. n Oil pump delivery line (45) through the valve (47) which controls the circuit at 190 - 195 bar (2755 - 2828 psi), at the base of the control valve tower (C). As a priority, for safety reasons, the oil satisfies the request from the trailer brake valve. Subsequently it meets a second valve (10) which, calibrated to 200 bar (2900 psi) controls the circuit. The oil is then distributed by the flow control valve (9) to the devices, if required otherwise it is sent to the tank (closed circuit). The closed centre system devices are: - Electronic lift (B) - Rear control valves (A) inside the tower, externally supplies also the EHR valves (Z1) and mechanical valves (Z). o. Oil which according to the requests from the circuit devices (n) pilots the flow control valve (9) (circuit load request). For the rear control valves (A) and the lift (B) it is inside the tower. From the tower head it leaves a pipe heading for the ventral control valves through which these pilot the flow control valve. Braking system. p. - p1. Oil from a sealed separate circuit which sends the right pedal (p) and left pedal (p1) to the rear brakes. Then if there is a trailer brake valve and braking on the front axle they pilot the logic valve, the oil (p) entering through port X1 and the oil (p1) entering through port X2. q. If the oil reaches the two ports X1 and X2 on the logic valve at the same time and at the same pressure, the valve opens and allows part of the oil to pass through the sealed circuit which will pilot: - with trailer brake valve, the head of the trailer brake valve spool (17) - with front brake, through the logic valve port X3 the head (30) of the logic valve on the front brake control valve (K) r. Oil from the circuit (n) which after the oil in circuit (q) has piloted the head of the trailer brake valve, passes through the flow regulator (18) and the valve (17)and is sent to: - for trailer brake valves Italy market, to the control valve (E) - for other markets, directly to the quick coupling (D) where the trailer brake pipe is attached r1. Oil from the trailer brake valve control valve (E) passes through the quick coupling to the trailer (F) and acts on the mechanical braking device (15), the pressure of this oil may be: - With parking brake disengaged, oil suction pump pressure sufficient without braking and with coupled pedals approx. 10 bar (145 psi) - With parking brake engaged 0 bar (0 psi) - With pump broken 10 bar (145 psi) - With parking brake disengaged, oil suction pump pressure sufficient without braking and with coupled pedals a pressure X acts on the brakes proportionally to that on the service brakes on the machine s. Oil output from the front braking control valve (K), is part of the low pressure circuit (d). It passes through the logic valve spool (31) and acts on the front brakes at a pressure according to the oil pressure in the sealed circuit (q) which pilots the control valve head (30). t. Oil discharged in the rear transmission casing.

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Tractors with 16 X16 â&#x20AC;&#x201C; 32 X 32 transmission (with creeper) with front axle braking, trailer brake valve, electronic lift, Bosch supplementary remote valve, and closed centre mechanical ventral control valve supplied with a fixed flow rate pump and front PTO.

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MOIL13TR01188JA

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Tractors with 16 X16 â&#x20AC;&#x201C; 32 X 32 transmission (with creeper) with front axle braking, trailer brake valve, electronic lift, Bosch supplementary remote valve, and closed centre ventral control valve supplied with a fixed flow rate pump and front PTO.

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MOIL13TR01187JA

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Hydraulic systems - Hydraulic systems

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hydraulic systems - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - 35 Fixed displacement pump - 104

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Hydraulic systems - 35 Fixed displacement pump - 104

FUNCTIONAL DATA Pump Overview General specifications of the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exploded view High pressure 80 Litres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Static description High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overview General specifications of the low pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exploded view Low pressure 80 Litres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Static description low pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Hydraulic systems - Fixed displacement pump

Pump - Overview General specifications of the high pressure pump

MOIL13TR01201FA

Fixed displacement pump 1 Suction oil filter 2 High Pressure Pump 3 Lift circuit pressure regulating valve (high pressure) Suction filter (1) Type Full-flow, screw-on cartridge Fixed to the pump body on suction side Call out reference Maximum operating pressure 7 bar (102 psi) By-pass valve mounted on the screw-on cartridge HBCV Calibration 0.8 bar (11.6 psi) Filtering capacity 42 μm High pressure circuit pump (2) - Flow rate 80 l/min (21 US gpm) Type Gear type, drawing oil from transmission housing Call out reference Flanged on the front left-hand side of the engine Driven by engine timing Control Direction of rotation (as seen from drive side) Clockwise Engine speed to pump speed ratio 1 : 1,125 2587 RPM Maximum speed of pump rotation (with engine at maximum power equivalent to 2300 RPM) Nominal flow rate 32.45 cm³/rev (1.98 in³/rev) Corresponding rated flow rate for new pump 83.948 l/min (22.18 US gpm) High pressure circuit pump (2) - Flow rate 61 l/min (16 US gpm) Type Gear type, drawing oil from transmission housing Call out reference Flanged on the front left-hand side of the engine Driven by engine timing Control Direction of rotation (as seen from drive side) Clockwise Engine speed to pump speed ratio 1 : 1,125 47538922 29/05/2013

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Maximum speed of pump rotation (with engine at maximum power equivalent to 2300 RPM) Nominal flow rate Corresponding rated flow rate for new pump Lift circuit pressure regulating valve Call out reference Calibration

2587 RPM 25.16 cm³/rev (1.54 in³/rev) 65.089 l/min (17.19 US gpm) Assembled immediately after the pump on the filter support, drains the oil suctioned to the filter 190 bar (2755 psi)÷ 195 bar (2828 psi)

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Hydraulic systems - Fixed displacement pump

Pump - Exploded view High pressure 80 Litres

MOIL13TR00295FA

Exploded diagram of the hydraulic lift system oil pump 1 High Pressure Pump 3 ”O-Ring” seal 5 Plastic anti-extrusion seal 7 Pump drive gear 9 Pump housing centring dowels on the end plate 11 End plate 13 Pump retaining screws, tightening torque 30 N·m (266 lb in) 15 Sealing 17 Bearing

2 End plate 4 Oil seal 6 Support blocks 8 Pump driven gear 10 Pump housing 12 Pump body retaining screws, tightening torque 63 N·m (558 lb in). 14 Transit movement joint 16 Snap ring

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Hydraulic systems - Fixed displacement pump

Pump - Static description High pressure pump â&#x20AC;˘ Oil is drawn by pump (1) from the rear transmission housing through the pipe (2). The oil enters the filter (3), through the pipe (4) and reaches the pump. The oil flows out of the pump through the pipe (5) and reaches the pressure regulating valve which (6) discharges excess oil drawn through the filter through the pipe (7)to the base of the remote valve stack.

MOIL13TR00255AA

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Hydraulic systems - Fixed displacement pump

Pump - Overview General specifications of the low pressure pump

MOIL13TR00256AA

Fixed displacement pump 1 Suction oil filter 2 Power steering / low pressure pump Suction filter (1) Type Location Maximum working pressure HBCV Calibration Filtering capacity Power steering pump (2) Type Location Control Direction of rotation (as seen from drive side) Engine speed to pump speed ratio Maximum speed of pump rotation (with engine at maximum power equivalent to 2300 RPM) Nominal flow rate Corresponding rated flow rate for new pump

Full-flow, screw-on cartridge Fixed to the pump body on suction side 7 bar (102 psi) By-pass valve mounted on the screw-on cartridge 0.8 bar (11.6 psi) 42 μm Gear type, drawing oil from transmission housing Flanged on the front left-hand side of the engine Driven by engine timing Clockwise direction 1 : 1,125 2587 RPM 16.76 cm³/rev (1.02 in³/rev) 43.358 l/min (11.45 US gpm)

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Hydraulic systems - Fixed displacement pump

Pump - Exploded view Low pressure 80 Litres

MOIL13TR00294FA

Exploded diagram of the hydraulic lift system oil pump 1 Low Pressure Pump 3 ”O-Ring” seal 5 Oil seal 7 Pump drive gear 9 Pump housing centring dowels on the end plate 11 End plate 13 Pump retaining screws, tightening torque 30 N·m (266 lb in)

2 End plate 4 Plastic anti-extrusion seal 6 Support blocks fixed by a dowel 8 Pump driven gear 10 Pump housing 12 Pump body retaining screws, tightening torque 57 N·m (504 lb in). 14 Transit movement joint

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Pump - Static description low pressure pump â&#x20AC;˘ Oil is drawn by pump (1) from the rear transmission housing through the pipe (2). The oil enters the filter (3), through the pipe (4) and reaches the pump. The oil leaves the pump via the pipe (5)and arrives at the hydraulic resonance damper (6). The oil flows through pipe (7)to the power steering valve (orbitrol), after passing through a filter and the low temperature pump protection valve.

MOIL13TR00255AA

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Index Hydraulic systems - 35 Fixed displacement pump - 104 Pump - Exploded view High pressure 80 Litres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pump - Exploded view Low pressure 80 Litres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Pump - Overview General specifications of the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pump - Overview General specifications of the low pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pump - Static description High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Pump - Static description low pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Hydraulic systems - 35 Regulated/Low pressure system - 322

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Hydraulic systems - 35 Regulated/Low pressure system - 322

FUNCTIONAL DATA Regulated/Low pressure system Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hydraulic systems - Regulated/Low pressure system

Regulated/Low pressure system - Hydraulic schema

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Hydraulic systems - Regulated/Low pressure system

MOIL13TR00962JA

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Hydraulic systems - Regulated/Low pressure system

A. Transmission lubrication control valve 1. Combined lubrication valve 2. Lubrication selector valve 3. Minimum lubricating pressure regulating valve 7 bar (102 psi) B. Heating cooler C. Accumulator D. Pressure filter E. Orbitrol, power steering motor F. Low Pressure Pump G. Suction filter H. Services control valve head 4. Power steering oil discharge inlet on low pressure regulating valve 17 - 18 bar (246 - 261 psi) 5. Lubrication pressure regulation valve 7.3 - 8.2 bar (106 - 119 psi) 6. Pressure exchanger by-pass valve 5.3 - 6.2 bar (77 - 90 psi) I. Services control valve: • Front and rear differential lock solenoid valve (if equipped) • Rear PTO solenoid • All-wheel solenoid valve • PTO brake solenoid valve • Creeper solenoid valve (if equipped) • Oil pressure sensor L. PTO assembly: • PTO Brake • PTO clutch • L M. Differential lock lubrication No. Rear differential lock O. Four wheel drive engagement P. Coupling solenoid valve control valve clutches C1, C2, C3 and C4 on the transmission Q. Shuttle coupling control valve - range 1-4 and 5-8 electro-hydraulic: • F forward solenoid valve • R reverse solenoid valve • Shuttle synchro position detector potentiometer • 1-4 first range solenoid valve • 5-8 second range solenoid valve • Range coupling synchro position detector potentiometer 7. Coupling synchro ranges 1-4 and 5-8 8. Forward and reverse coupling synchro Oil in suction Oil at pressure, low pressure coupling 17 - 18 bar (246 - 261 psi) Discharge oil

Oil to lubrication 7.3 - 8.2 bar (106 - 119 psi) Power steering oil

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Index Hydraulic systems - 35 Regulated/Low pressure system - 322 Regulated/Low pressure system - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hydraulic systems - 35 Remote control valves - 204

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Hydraulic systems - 35 Remote control valves - 204

TECHNICAL DATA Remote control valve Closed center mechanical remote valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Closed center mechanical remote valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Closed center mechanical remote valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Remote control valve Dynamic description Splitter operation (where installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Remote control valve control lever Adjust spool valve control flexible cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

Remote control valve Closed center mechanical remote valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Closed center mechanical remote valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Closed center mechanical remote valve - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Couplers Service instruction QUICK COUPLER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

DIAGNOSTIC Couplers Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve - Special tools CAUTION The operations described in this section can only be carried out with the ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. B008

List of specific tools required for the various operations described in this section. 297612 Lifting bracket.

Remote control valve Closed center mechanical remote valve General specification Remote Control Valve Output @ 100 bar (1450.0 psi) @ 2200 erpm Detent Regulating Valve Pressure

90 l/min (23.8 US gpm) Pre set non adjustable

Remote control valve Closed center mechanical remote valve Torque

BVE0601A

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Hydraulic systems - Remote control valves

Remote control valve - Dynamic description Splitter operation (where installed)

WLAPL4S35C303G

(A)series tractor. - Oil from the control valve quick coupler. (B)series tractor. - Oil from the control valve quick coupler. (C)series tractor. - Splitter additional quick coupler oil. (D)series tractor. - Splitter additional quick coupler oil. (E)series tractor. - Splitter quick coupler oil. (F)series tractor. - Splitter quick coupler oil. (T)series tractor. - Oil at exhaust. (X)series tractor. - Splitter spool pilot oil, come the transmission control valve.

(1)series tractor. - Splitter spool compartment caps. (2)series tractor. - Spool positioning spring. (3)series tractor. (4)series tractor. (5)series tractor. (6)series tractor. (7)series tractor. (8)series tractor.

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- Splitter spool. - Spool piloting line one-way valve. - Splitter main quick couplers. - Splitter solenoid valve. - Supplementary main quick couplers. - Splitter body.

Hydraulic systems - Remote control valves

WLAPL4S35C304G

: discharged oil. : Static oil. : Pressurised oil. : Oil at pilot pressure from transmission control valve. (A)series tractor. - Oil from the control valve quick coupler. (B)series tractor. - Oil from the control valve quick coupler. (C)series tractor. - Splitter additional quick coupler oil. (D)series tractor. - Splitter additional quick coupler oil. (E)series tractor. - Splitter quick coupler oil.

(F)series tractor. - Splitter quick coupler oil. (1)series tractor. -Splitter hydraulic schematic. (2)series tractor. - Splitter with solenoid valve (energized). (3)series tractor. - Splitter with solenoid valve resting.

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Hydraulic systems - Remote control valves

1. If you wish to use the splitter to have two additional quick couplers, press the button (2) on the lever (1), then activate the lever at the same time.

WLAPL4S35C301A

MOIL13TR00443AA

2. Refer to 2 situation 2. The oil from the pipe connecting the accumulator (or transmission control valve) and the services control valve through the line (1), enters the splitter and, through the energized solenoid valve, goes to the spool and moves it to the left, deviating the oil from the supplementary control valve ( (A) and (B), 2) to the supplementary outlets ( (C) and (D), 2). 3. If you wish to use the control valve without pressing the button ( (1), 3), the spool will stay in the position determined by the thrust of the spring on the left of the spool (refer to 2 situation 3). The oil from the supplementary control valve ( (A) and (B), 2) will be deviated to the supplementary outlets ( (E) and (F), 2).

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Hydraulic systems - Remote control valves

Remote control valve control lever - Adjust spool valve control flexible cables. T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

Adjust the flexible cable with the nut ( (1) , 2 ) on the block of valves, so that the lever (1) , in the cab, in the neutral position, is at a distance (L) = 55 mm (2.1654 in) from the bottom of the slot in which it slides.

Repeatedly try engaging the spool valve and check there is no interference between the lever and the bottom of the slot preventing its travel.

If there is interference then change the adjustment on the block of valves and check again.

WLAPL4S35C303A

WLAPL4S35C304A

Proceed in the same manner on the other two levers.

NOTE: After mounting the levers, run the flexible cables out of the back of the cab, taking care to keep them parallel to each other, without crossing.

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve - Disassemble 1.

Remove the remote control valve quick release coupling manifolds (1). The couplers are serviced as an assembly and should not be disassembled.

BVE0474A

BVE0483A

BVE0484A

Remove the remote control valve control cable retaining bracket.

Remove the remote control valve end cover retaining nuts. Remove the remote control valve end cover.

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Hydraulic systems - Remote control valves

Remove the remote control valve slices from the remote control valve base manifold.

BVE0485A

BVE0480A_414

Mechanical Remote Control Valve Components 1 Flow Control Adjuster 3 Load Holding Check Valve 5 Lock Valve

2 Flow Control Spool 4 Main Control Spool 6 Spool Centering and Detent Mechanism

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Hydraulic systems - Remote control valves

Disassemble the remote control valve slice using the following instructions and illustrations. Remove the O-ring (1) and the check valve (2). Remove the flow control adjuster knob (1) and unscrew the flow control adjuster from the remote control valve body.

BSB0388A_415

BSB0394A

BSB0385A

Prior to removing the control valve spool ensure the flats (1) on the end of the spool are in the vertical position as shown. Remove the remote control valve main control spool.

CAUTION Do not rotate the main control spool or use force once inserted into the bore, otherwise damage to the main control spool and the lock valve pin will occur. B004

Remove the lock valve from the raise port as follows:Using a small screwdriver, open the two slots (1) on the keeper (2) and turn the keeper through 90 Â°. Remove the spring seat (3) from the remote control valve housing. Remove the lock valve.

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Hydraulic systems - Remote control valves

BSB0386A

Lock Valve 1 3 5 7

Plunger Ball Washer Spring Seat

2 4 6 8

Lock Valve Spring Spring Keeper

WARNING A large spring is positioned beneath the plug, take extreme care when removing plugs. B041

BSB0393A

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Hydraulic systems - Remote control valves

BSB0396B

Flow Control Spool and Load Hold Check Valve (Early type with ball) 1 Flow Control Spool 3 Spring Guide 5 Plastic Cap 7 Plug 9 `O' Ring 11 Load Hold Check Valve Ball

2 Spring 4 Plug and `O' Ring 6 Retainer 8 Backup Ring 10 Spring

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Hydraulic systems - Remote control valves

BAIL06CCM211FSA

Flow Control Spool and Load Hold Check Valve (Later Type with cone) 2 Retainer 4 Spring Guide 6 Plastic Cap 8 Plug 10 'O' Ring 12 Check Valve Cone

1 Flow Control Spool 3 Spring 5 Plug and 'O' Ring 7 Retainer 9 Back-up Ring 11 Spring

Lift Check Valve Removal 9.

Remove the plastic cap (6) and the snap ring (7) Figure 10, taking care not to scratch the bore.

10.

Locate and clamp the extractor tool 380002720 onto the retainer (1) by tightening the nut on the tool (2).

BAIL06CCM222ASA

11.

Pull out the tool and retainer.

12.

Remove the check valve and spring.

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Hydraulic systems - Remote control valves

BSB0498A

Main Control Spool 1 End Cap 3 Shims 5 Main Control Spool 7 `O' Ring 9 Back-Up Ring 11 Ball 13 Spring 13.

2 `O' Ring 4 Spool Centring Mechanism 6 `O' Ring 8 Spacer 10 Detent Release Orifice 12 Plunger 14 Spring Seat

Remove the main control spool (5) by removing the spool centring mechanism (4).

NOTE: It is not recommended that the spool centering mechanism (4) is disassembled. 14.

Housed within the centre of the remote control valve main control spool (5) is the detent release orifice (10). This is factory preset and servicing should be restricted to washing in an approved degreasing agent without removing the orifice from within the spool.

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Assemble

BSB0498A

Control Valve Spool 1 End Cap 3 Shims 5 Spool 7 `O' Ring 9 Back-Up Ring 11 Ball 13 Spring 1.

2 `O' Ring 4 Spool Centring Mechanism 6 `O' Ring 8 Spacer 10 Detent Release Orifice 12 Plunger 14 Spring Seat

Prior to inserting the control valve spool into the housing, ensure the flats (1) on the end of the spool are in the vertical position as shown, then install the load holding check valve, as described below.. Do Not rotate the spool after installing the load holding valve otherwise damage to spool and load holding valve plunger will occur.

WARNING Do not rotate the main control spool or use force once inserted into the bore, otherwise damage to the main control spool and the lock valve pin will occur. B004 BSB0508A

Install the control valve spool. Retain by screwing on the spool centering mechanism.

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Hydraulic systems - Remote control valves

BSB0386A

Load Check Valve 1 3 5 7 3.

Plunger Ball Washer Spring Seat

2 4 6 8

Load Holding Valve Spring Spring Keeper

Load check valve installation Dimensions: L = Plunger Length Z = Depth to the Plunger Y = Depth to the Pilot Ball B = Pilot Ball diameter ( 4 mm (0.16 in) X = Gap between the Plunger and the Pilot Ball

NOTE: When the control valve is in the neutral position there must be a gap (X) 0.2 - 0.3 mm (0.008 - 0.012 in) between the plunger and the pilot ball.

BAIL06CCM194ASA

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Hydraulic systems - Remote control valves

Calculating Gap (X) 4.

Install the shortest plunger (No rings , 15.07 mm (0.59 in) in position with the control valve in neutral.

Measure dimension `Z` from the top of the plunger to the top face of the remote valve body (e.g. 36.43 mm (1.43 in) ).

Remove the plunger.

Install the load check valve and the pilot ball. Ensure that both are fully seated.

Measure dimension `Y` from the top of the ball to the top face of the valve body (e.g. 36.43 mm (1.43 in).

Load Check Valve Installation 9.

Ensure that the control spool is in neutral.

10.

Install the determined plunger using long nosed pliers.

11.

Install the lock valve, pilot ball, pilot spring, washer and the spring (Refer to Figure 3).

12.

Use a screwdriver to bend both retainer lugs (1) (figure 6) upwards, and locate the retainer to the bore.

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BAIL06CCM195ASA

BAIL06CCM196ASA

Hydraulic systems - Remote control valves

13.

Fit the spring seat into the retainer, straighten the lugs and turn the assembly counterclockwise 90 Â° to secure in the remote valve body.

BAIL06CCM197ASA

BAIL06CCM198ASA

BAIL06CCM199ASA

Flow Control Valve Installation 14.

Install the flow control spool valve (1), together with the spring (2), guide (3) and retaining plug (4). Tighten the retaining plug to a torque of 67 Nm (49.42 lbft)

Flow Control Regulator Installation 15.

16.

Assemble the flow control regulator (1) with `O` rings (7), (8), and (9).

Screw the flow control regulator into the valve body.

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Hydraulic systems - Remote control valves

17.

Using a screwdriver, turn the restrictor clockwise as far as it will go, and then turn back 60 Â°(minimum flow position).

18.

Install the clamp, rotary knob (2), washer and the nut to the restrictor stem. Ensure that the rotary knob lug is located to the left of the stop pin (1).

19.

Tighten the nut to a torque of 3 Nm (2.213 lbft) without rotating the restrictor.

20.

Install the cap with the groove facing the knob lug.

21.

Check the minimum and maximum flow available from the remote valve using a flow meter. If the rotary knob has been installed as described above the minimum flow should be approximately 10 l/min (2.64 US gpm) and the maximum flow should be approximately 80 l/min (21.13 US gpm).

BAIL06CCM200ASA

BAIL06CCM201ASA

Lift Check Valve Installation 22.

Check the bore for any rough edges and smooth if necessary.

23.

Install the check valve (1) into the remote valve body.

24.

Fit the back up ring (6) and the 'O' ring (7) in the groove in the retainer (3) and locate the spring (2) onto the inner spigot of the retainer.

25.

Locate the snap ring (4), retainer and spring assembly onto the installation tool 380002720 (5). Install the assembly into the remote valve bore and push until the tool handle contacts the remote valve body.

26.

The snap ring must be located in the groove. Ensure that the retainer is located up against the snap ring. Install a new plastic cap.

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Hydraulic systems - Remote control valves

Load Sense Check Valve Installation 27.

Install new 'O' Ring seal and back up ring.

NOTE: Clearance 'X' should be approximately 0.5 mm (0.020 in) from the flange face of the valve segment to the top edge of the inserted check valve.

BAIL06CCM139ASA

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve - Travel adjust NOTE: Ensure the remote control valve is in neutral before proceeding. 1.

Remove the remote control valve cable lock nut.

BVE0460A

BVE0532A

BVE0460A_413

Adjust the remote control valve cable adjustment nut. Adjustment is correct when all the positions are available (eg. extend, neutral, retract, and float). Repeat steps 1-3 for the remaining remote control valve cable(s).

Install the remote control valve cable lock nuts.

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Hydraulic systems - Remote control valves

Couplers - Service instruction QUICK COUPLER MAINTENANCE INTRODUCTION The main causes for poor operation or breakage of the quick couplers are: - dirt; - type of male quick coupler not compatible, or damaged (dents, for instance); - forced extraction of the mail coupler when there is pressure in the hydraulic system. ATTENTION: Before removing the protective caps for the male connections, remove all the debris that has accumulated on the pressure points to avoid contaminating the hydraulic system. Before disconnecting the couplers you must: - lower the connected attachments; - stop the engine; - move the relevant levers forwards and backwards to discharge pressure from the hydraulic system.

MAINTENANCE OPERATIONS The correct procedure in using and servicing the hydraulic connections is vital for their durability and efficiency. There follow helpful tips for using the quick couplers correctly and avoiding operational trouble. If the female couplers are not used, always protect the male ones with the special plugs provided.

SEZ35CAP3A-25

SEZ35CAP3A-5

Spray solvent for a few seconds into the gap between the movable outer portion (1) of the male connection and the inner portion (2) supporting the balls.

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Hydraulic systems - Remote control valves

Spray solvent for a few seconds into the coupling zone and on the locking balls.

SEZ35CAP3A-26

SEZ35CAP3A-27

Perform some hooking/unhooking operations and if necessary do the cleaning again to make the coupling fluid.

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Hydraulic systems - Remote control valves

Couplers - Troubleshooting Problem Couplers - Not engage (35.204.BB-G.10.B.14) Couplers - Hard to operate (35.204.BB-G.10.C.14) Couplers - Oil leakage (35.204.BB-G.10.D.10)

Possible Cause

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Correction

Index Hydraulic systems - 35 Remote control valves - 204 Couplers - Service instruction QUICK COUPLER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Couplers - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Remote control valve - Dynamic description Splitter operation (where installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remote control valve Closed center mechanical remote valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remote control valve Closed center mechanical remote valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remote control valve Closed center mechanical remote valve - General specification . . . . . . . . . . . . . . . . . . . . . . . 3 Remote control valve Closed center mechanical remote valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remote control valve Closed center mechanical remote valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remote control valve Closed center mechanical remote valve - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Remote control valve control lever - Adjust spool valve control flexible cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

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Hydraulic systems - 35 Three-point hitch control valve - 114

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Hydraulic systems - 35 Three-point hitch control valve - 114

TECHNICAL DATA Electronically-controlled hitch valve Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Electronically-controlled hitch valve Dynamic description operation of hydraulic draft control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Electronically-controlled hitch valve Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Hydraulic systems - Three-point hitch control valve

Electronically-controlled hitch valve - Calibration Situated Cylinder safety valve

VALVE CALIBRATION In the spool valve EDC 197 - 210 bar (2856.50 - 3045.00 psi)

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Hydraulic systems - Three-point hitch control valve

Electronically-controlled hitch valve - Dynamic description operation of hydraulic draft control valve Components of the EDC control valve

WLAPL4S35C604G

(1)series tractor. (2)series tractor. (3335.00 psi) (3)series tractor. (4)series tractor.

Load-holding valve Lift cylinder pressure relief valve 230 bar

(5)series tractor. Raise solenoid (6)series tractor. Lifting rod

Lowering metering valve Lower solenoid valve

(7)series tractor. Flow Compensating Valve

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Hydraulic systems - Three-point hitch control valve

operation The main components of the Electronic Draft Control system are:

Flow Control Spool This spool adjusts the oil flow from the parallel duct crossing the centre of the control valve EDC to the hydraulic lift. The valve compares the parallel duct pressure with the hydraulic lift operating pressure and adjusts the delivery to the latter circuit according to the needs of the lift.

Lifting rod The lift spool sends oil to the lift circuit and is directly controlled by the relative PWM valve.

Raise solenoid The raise solenoid valve is a PWM valve, controlled by the Electronic Draft Control microprocessor which proportionally modulates it according to the required lifting speed.

Load-holding valve The load check valve prevents the static oil in the lifting cylinder from returning to the reservoir. This valve opens only when the pressure in the lift spool exceeds that of the static oil in the lifting cylinder.

Lift cylinder relief valve This valve protects the lifting cylinder from load peaks (hammering) and cuts in at 230 bar (3335.00 psi).

Lower solenoid valve The lower solenoid valve has the same operating configuration as the lift PWM valve. It is also enabled by the microprocessor and controls the lowering metering valve to maintain the required descent speed of the implement.

Lowering metering valve The lowering metering valve adjusts the quantity of oil from the lifting cylinder to the reservoir when the hydraulic lift is lowered. It is enabled by the relative PWM valve.

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Hydraulic systems - Three-point hitch control valve

Neutral position NOTE: the hydraulic lift cylinder is single acting and consequently has only one coupler for lifting and lowering the lift arms. When the hydraulic lift is in neutral position, the control solenoid valves are off. The oil runs from the parallel duct ‘ (A)’ through the flow compensation spool and then into the duct ‘ (B)’, where it remains blocked by the lift spool grooves. Oil under pressure in the hydraulic lift circuit is prevented from entering duct ' (5)' by the load check valve (E) ’. The pressurised static oil in the lift circuit acts on the RH side of the metering valve, through the calibrated hole ‘ (X) ’.The pressure applied in this way maintains the metering valve in the closed position, preventing the oil from the duct ‘ (E) ’ from returning to the reservoir through the duct ‘ (F)’ . When the control valve is in the neutral position, the duct ‘ (C)’ and load sensing duct ‘ (D) ’ are connected to the reservoir through the central section of the lift spool and the duct ‘ (F) ’. The duct ‘ (G) ’ is the common return pipe to the reservoir, and runs through the centre of the control valve assembly stack.

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Hydraulic systems - Three-point hitch control valve

WLAPL4S35C605G

: Pump delivery : Static oil : Return to reservoir (1)series tractor. (2)series tractor. (3)series tractor. (4)series tractor.

Raise solenoid Lifting rod flow compensator spool Load-holding valve

(5)series tractor. Lift cylinder safety valve 230 bar (3335.00 psi) (6)series tractor. Lowering metering valve (7)series tractor. Lower solenoid valve

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Hydraulic systems - Three-point hitch control valve

Raise When the hydraulic lift is raised by the operator controls, or when the electronic control system automatically reduces the working depth of the implement, the microprocessor excites the lift PWM valve. The controlled excitation of the solenoid valve by the microprocessor allows the vale to move the spool to the right in proportion to the lift percentage required by the system. When the system pressure is sufficient to lift the check valve (5) from its seat, the oil runs from the duct ‘ (C) ’ to the duct ‘ (E) ’ and enables the lift cylinder. The oil pressure in the circuit acts on the right side of the metering valve ‘ (H) ’ through the calibrated hole ‘ (X) ’, keeping the valve and preventing the oil from entering the duct ‘ (E) ’ and returning to the reservoir through the duct (F) . The working pressure of the hydraulic lift cylinder is measured in the duct ‘ (C) ’ and the load sensing duct ‘ (D) ’, which adjusts the delivery to the hydraulic pump. See Remote control valve - Dynamic description (35.204) ’Closed centre remote valves’ for more details on the operation of the load sensing circuit. The pressure in the duct ‘ (C) ’ counteracts the spring on the right end of the flow control spool, while, at the same time, the system pressure in the duct ‘ (B) ’ acts on the left end of the same spool. The pressure differential on the two ends of the flow control spool make the latter move until it finds a balanced position, automatically adjusting the oil flow running from the parallel duct ’ (A)’ to the metering grooves ‘ (Y)’ and through the ducts ‘ (C)’ and ’ (E)’, to the lift cylinder. The flow control spool is essential for ensuring that the flow from the parallel duct ‘ (A)’ to the hydraulic lift is metered precisely, independently of the working pressure of any auxiliary control valves operating on the hydraulic lift at the same time. When the lift arms reach the required height, the microprocessor cuts off the signal to the solenoid valve and the lift spool is moved to the left by the spring, returning to the neutral position. If the lift arms suffer load peaks (hammering) and the hydraulic lift circuit pressure exceeds 200 bar (2900.00 psi), the (maximum) safety valve in the lift cylinder drains off the excess pressure in the reservoir. Figure 3 shows the oil flow in the flow control spool when the hydraulic lift circuit works at the highest pressure of the whole system. Figure 4 shows the flow control spool operation when the hydraulic lift runs at a lower pressure but at the same time as an auxiliary control valve running at higher pressure. In this situation, the system pressure in the parallel duct ‘ (A)’ is greater than the working pressure of the hydraulic lift.

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Hydraulic systems - Three-point hitch control valve

Control valve EDC â&#x20AC;&#x201C; Lifting (high pressure lifting)

WLAPL4S35C606G

: Pressurised oil pipe, from pump : Return to reservoir (1)series tractor. (2)series tractor. (3)series tractor. (4)series tractor.

Raise solenoid Lifting rod flow compensator spool Load-holding valve

(5)series tractor. Lift cylinder safety valve (6)series tractor. Lowering metering valve (7)series tractor. Lower solenoid valve

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Hydraulic systems - Three-point hitch control valve

Control valve EDC â&#x20AC;&#x201C; Lifting at low pressure at the same time as the auxiliary control valves running at higher pressure

WLAPL4S35C607G

: Pressurised oil pipe, from pump : Hydraulic lift pressure (lower than the pump pressure) : Return to reservoir (1)series tractor. (2)series tractor. (3)series tractor. (4)series tractor.

Doser metering valve Flow compensator spool Lifting rod Raise solenoid

(5)series tractor. Load-holding valve (6)series tractor. Lift Cylinder Safety Valve (7)series tractor. Lower solenoid valve

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Hydraulic systems - Three-point hitch control valve

Lower The hydraulic lift arms are lowered by control venting the oil in the hydraulic lift cylinder into the reservoir through the lowering metering valve.

Lowering metering valve 1. Gear 2. Metering spool 3. Pilot spool 4. Core Plug 5. Snap ring WLAPL4S35C613A

WLAPL4S35C614A

WLAPL4S35C615A

The lowering cycle takes place in: The PWM valve is excited and the small piston (1) moves the pilot spool to the right (6). The oil trapped on the right hand end of the lowering valve ` (H)' is now control vented over the grooves in the pilot spool (2) to the reservoir through the duct. (F) ’.The pressure of the oil in the duct ‘ (E)’ of the lift cylinder acts on the bevelled side (4) of the metering spool (3), moving it to the right.

The oil from the lift cylinder runs along the metering grooves (5) on the valve and returns to the reservoir, allows the arms to be lowered by gravity under the weight of the implement. The lowering speed is electronically controlled by the microprocessor and the lowering PWM valve, which adjusts the clearance above the metering grooves (5)

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Hydraulic systems - Three-point hitch control valve

Control valve EDC - Lowering (1)

WLAPL4S35C608G

: Pressurised oil pipe, from pump : Static oil : Return to reservoir (1)series tractor. (2)series tractor. (3)series tractor. (4)series tractor.

Raise solenoid Lifting rod Flow compensator spool Load-holding valve

(5)series tractor. Lift Cylinder Safety Valve (6)series tractor. Lowering metering valve (7)series tractor. Lower solenoid valve

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Hydraulic systems - Three-point hitch control valve

Control valve EDC - Lowering (2)

WLAPL4S35C609G

: Pressurised oil pipe, from pump : Return to reservoir (1)series tractor. (2)series tractor. (3)series tractor. (4)series tractor.

Raise solenoid Lifting rod Flow compensator spool Load-holding valve

(5)series tractor. Lift Cylinder Safety Valve (6)series tractor. Lowering metering valve (7)series tractor. Lower solenoid valve

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Hydraulic systems - Three-point hitch control valve

Electronically-controlled hitch valve - Disassemble Components of the control spool valve EDC

WLAPL4S35C604G

(1) . (2) . (3) . (4) .

Load check valve Lift cylinder relief valve 230 bar (3335.00 psi) Cartridge of the lowering dosing valve Lowering solenoid valve

(5) . Raise solenoid valve (6) . Raise spool (7) . Flow Compensating Valve

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Hydraulic systems - Three-point hitch control valve

Remove the O-ring (1) and load sensing check valve (2) .

WLAPL4S35C635A

WLAPL4S35C617A

WLAPL4S35C616A

WLAPL4S35C618A

Remove the load check valve (1) . Valve (2) . Washer (3) . Guide (4) . Circlip (5) . Plug (6) . Washer (7) . Spring (8) . Rubber seal

Unscrew the knob (1) and remove the Oâ&#x20AC;&#x201C;ring (2) and the coil (3) from each solenoid valve (4) .

Unscrew and remove the six Allen screws and remove the retaining plate (1) . Remove the cores of the solenoids (2) and the Oâ&#x20AC;&#x201C;rings (3) .

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Hydraulic systems - Three-point hitch control valve

Remove the lifting cylinder safety valve. (1) . Seat (2) . Valve (3) . Spring (4) . Copper washer (5) . Shims (6) . End Cap

ATTENTION: Take great care when removing the plug (4) since there is a large spring underneath it.

Make a box wrench (1) from a section of steel pipe with an inside diameter of 18 mm (0.71 in) and remove the seat of the lifting cylinder safety valve (2) .

Remove the flow compensating spool (1) .

WLAPL4S35C619A

WLAPL4S35C620A

WLAPL4S35C621A

Remove the solenoid valve unit (4) , O-ring (3) , lifting spool (2) and spring (1) .

ATTENTION: Take great care when removing the plug (4) since there is a large spring underneath it (3) .

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Hydraulic systems - Three-point hitch control valve

To remove the lowering dosing valve it is necessary to disassemble the valve in stages as described below.

10.

With a 4 mm (0.1575 in) Allen wrench, unscrew and remove the plug on the bottom side of the spool valve section EDC .

WLAPL4S35C622A

11.

Use a length of hexagonal bar size 14 mm (0.5512 in) with a hole size 11 mm (0.4331 in) made in the center to screw the nozzle (1) further into the valve body. This will slacken off the pressure of the dosing valve spring on the circlip (2) .

12.

Remove the circlip (2) , seat (3) and spring (4) .

13.

Remove the nozzle.

14.

WLAPL4S35C623A

WLAPL4S35C624A

WLAPL4S35C625A

Remove the locking ring (1) with the aid of a length of hexagonal bar size 17 mm (0.6693 in) (1) with a hole size 11 mm (0.4331 in) made in the center.

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Hydraulic systems - Three-point hitch control valve

15.

16.

Extract the dosing cartridge (1) from the valve body.

WLAPL4S35C626A

WLAPL4S35C627A

Disassemble the dosing cartridge components. (1) . Sleeve (2) . Dosing cartridge (3) . Pilot spool (4) . Plug (5) . Circlip

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Hydraulic systems - Three-point hitch control valve

Components of the dosing valve

WLAPL4S35C610G

(1) (2) (3) (4) (5) (6)

. . . . . .

Locking screw Sleeve Plug Locking screw Calibrated hole Shim

(7) . Dosing valve (8) . Locking ring (9) . Nozzle (10) . Seat (11) . Circlip

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Hydraulic systems - Three-point hitch control valve

Electronically-controlled hitch valve - Assemble 1.

For assembly operations, follow the disassembly operations in reverse order.

When installing the nozzle (5) and the locking ring (6) , check that the calibrated orifice with the toothed edge and the nozzle are aligned with the locking screws (1) and (4) . See Electronically-controlled hitch valve - Disassemble (35.114) last illustration.

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Index Hydraulic systems - 35 Three-point hitch control valve - 114 Electronically-controlled hitch valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electronically-controlled hitch valve - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electronically-controlled hitch valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electronically-controlled hitch valve - Dynamic description operation of hydraulic draft control valve . . . . . . . . . . . 4

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47538922 29/05/2013 EN

SERVICE MANUAL Hitches, drawbars, and implement couplings

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Hitches, drawbars, and implement couplings - 37

[37.110] Rear three-point hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

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Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110

TECHNICAL DATA Rear three-point hitch General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Rear three-point hitch External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Rear hitch housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - General specification Main specification of implement hitching device Type Category: Draft Control Stabilizer devices Stabilisers Lower links Draft Control

three-point linkage 2nd by means of lower arms with draft sensors transverse telescopic (standard) fast-coupling or telescopic (on request) by means of lower arms with draft sensors MAXIMUM LIFT CAPACITY With vertical rods pivoting in the rear hole of the horizontal arms and top link connected to the upper hole of the top link support with the centre of gravity at 610 mm (24.0157 in) from the ends of the arms, with maximum working pressure:

â&#x20AC;˘ with horizontal arms without supplementary cylinders

3191 kg (7035 lb)

â&#x20AC;˘ with two supplementary cylinders (on request)

5424 kg (11958 lb)

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Torque

WLAPL4S35C602G

PARTS TO BE TIGHTENED Solenoid valves fixing screws (C1) Spool valve fitting (C2) Lift casing fixing screws (C3) Bolts fixing pack of spool valves and EDC (C4) Draft sensing pins fixing screws (C5)

Tightening Nm (lbft) 3.7 - 4.4 N·m (2.73 - 3.25 lb ft) 65 - 75 N·m (47.94 - 55.32 lb ft) 142 N·m (104.73 lb ft) 30 N·m (22.13 lb ft) 48 N·m (35.40 lb ft)

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torque kgm 0,37÷0,44 Kgm 6,62÷7,64 Kgm 14,47 Kgm 3,05 Kgm 4,89 Kgm

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - External view

WLAPL4S35C603G

(1) . (2) . (3) . (4) .

- Oil line to the left supplementary cylinder. - Arms height potentiometer. - Potentiometer control device. - Left supplementary cylinder.

(5) . - Left lift arm. (6) . - Lowering solenoid valve.

(7) . - Lifting solenoid valve. (8) . - Electronic lift spool valve EDC . (9) . - Fitting for sending oil to the cylinders. (10) . - Line for sending oil from the spool valve to the cylinders. (11) . - Lift casing

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear hitch housing - Remove 1.

Raise the right step and open the retainer (1), remove the battery cover by the retainer (2), disconnect the negative battery cable.

Chock the front wheels with wedges.

Using a hoist and cable (1) raise the rear part of the tractor, positioning two fixed stands under the side drives, then remove the right-hand and left-hand wheels (2).

MOIL12TR00670AA

MOIL12APL0085AA

MOIL12APL0058AA

Disconnect the locking pin (1) and the support pin (2), then remove the third point (3).

Disconnect the vertical tie-rods (1) from the lift arm (on both sides).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Remove the snap ring (2), the union (4), the bracket retaining bolts (5) and remove the extra jack (on both sides).

Take out the screws (1) fastening the cab support bracket to the gearbox.

Slightly raise the cab and position a suitable piece of wood between the cab supports and the drive housing, making sure not to crush any piping or wiring during the procedure.

10.

MOIL12APL0086AA

MOIL12APL0039AA

MOIL12APL0059AA

MOIL12APL0060AA

Disconnect the two pipes (1) from the trailer brake valve (if fitted) to the rear brakes, the electrical connector (2) to the two solenoids on the lift control valve, the load sensing valve pilot pipe (3), and the oil recovery pipes (4) from the quick couplers.

Disconnect the spool pilot pipes (1) and exhaust pipes (2) diverter. Disconnect the feed pipe from the pump to the control valve blocks (3) and the ventral control valves (4) (if fitted). If fitted, disconnect the connection pipe from the trailer brake valve to the Italy control valve (5) and the electrical connector to the pressure sensor on the trailer brake valve.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

11.

12.

Disconnect the control rods (1) from the control valve levers.

MOIL12APL0061AA

Using a suitable hoist, support the auxiliary control valve assembly, remove the retaining bolts (1) and extract the assembly from the tractor. Set the assembly on a bench.

13.

If fitted, detach the gear-synchronized PTO transmission lever.

14.

Disconnect the lift arm position potentiometer connection, detach and remove the tie-rod (1).

15.

WLAPL4S90C123A

MOIL12APL0051AA

MOIL12APL0087AA

Disconnect the PTO brake control piping (1).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

16.

17.

Disconnect the third point support bracket (1). Remove the lift housing retaining bolts (2) from the transmission housing.

MOIL12APL0088AA

MOIL12APL0089AA

MOIL12APL0090AA

Secure the tool 380000238 (1) to the lift.

18.

Connect tool 380000224 (2) to the hoist and to tool 380000238 (3), raise the hydraulic lift unit by a few centimetres, extract from the rear part, tilting the unit to avoid the internal breather pipe.

19.

If necessary, detach the gear-synchronized PTO transmission lever (1), this will make the aforementioned operation easier.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear hitch housing - Install To refit the hydraulic lift on the transmission casing, proceed as follows: 1.

Before reassembling the hydraulic lift on the rear transmission housing, carefully clean and degrease the mating surfaces, then apply sealing compound approx. 2 mm (0.0787 in) along the marked line shown in the drawing (see. Rear axle housing - Exploded view (27.100)).

- Assemble the hydraulic lift using tools 380000238 and 380000224.

Secure the lift and potentiometer with the relative bolts.

Connect the P.T.O. control line.

Connect the potentiometer connection, the relative tie-rod and the gear-synchronized PTO lever.

Mount the auxiliary control valve assembly on the lift housing.

Connect the flexible control valve cables and adjust them according to (see. Remote control valve control lever - Adjust (35.204)).

Connect the pipes to the diverter and the trailer brake valve, if fitted.

Connect the auxiliary control valve piping.

10.

Connect the power take-off speed sensor connection.

11.

Secure the third point push rod support bracket.

12.

Remove the wooden blocks and secure the rear cab support rods to the drive casings.

13.

Assemble and secure the extra jacks.

14.

Attach the vertical tie-rods.

15.

Fit the third point top link.

16.

Position and secure the rear wheels.

17.

Connect the negative cable to the battery, put the cover back on and lower the right-hand steps.

18.

Check the transmission oil level and top up if required (see. Consumables ()) can be varied.

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Index Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110 Rear hitch housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Rear hitch housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear three-point hitch - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rear three-point hitch - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear three-point hitch - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47538922 29/05/2013 EN

SERVICE MANUAL Steering

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Steering - 41

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[41.106] Tie rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

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Steering - 41 Steering control - 101

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Steering - 41 Steering control - 101

SERVICE Steering column Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Steering - Steering control

Steering column - Visual inspection 1.

Inspect the steering shaft universal joint and lower rubber coupling. Replace if any free play is evident.

Inspect the column assembly, if damaged or the bushes are worn a new assembly will be required.

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Steering - Steering control

Steering column - Remove Prior operation: Remove the steering wheel. 1.

Remove the instrument cluster upper retaining screw. Repeat step for the right-hand side. Detach the enhanced keypad panel.

BAIL07APH455AVB

BAIL07APH456AVA

BAIL07APH455AVC

Disconnect the enhanced keypad electrical connector. Remove the enhanced keypad panel.

Detach the instrument cluster.

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Steering - Steering control

Disconnect the instrument cluster electrical connectors and remove the instrument cluster.

BAIL07APH457AVA

BAIL07APH458AVA

BAIL07APH459AVA

BAIL07APH460AVA

Remove the steering column lower shroud retaining bolts.

Remove the steering column lower shroud.

Remove the steering column shroud left-hand retaining screws.

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Steering - Steering control

Remove the steering column shroud right-hand retaining screws and ignition switch retaining nut.

BAIL07APH461AVA

BAIL07APH462AVA

Remove the steering column shrouds.

Vehicles with Fast Steer™ 10.

Disconnect the six electrical connectors.

BAIL07APH520AVA

BAIL07APH463AVA

Vehicles without Fast Steer™ 11.

Disconnect the four electrical connectors.

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Steering - Steering control

12.

13.

Remove the steering column to frame retaining bolts. Repeat step for the right-hand side.

BAIL07APH464AVA

BAIL07APH466AVB

Remove the lower steering column retaining bolts. Remove the steering column.

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Index Steering - 41 Steering control - 101 Steering column - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Steering column - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Steering - 41 Tie rods - 106

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Steering - 41 Tie rods - 106

SERVICE Tie rods Toe in adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Steering - Tie rods

Tie rods - Toe in adjust When travelling forward in a straight path, the wheels of four-wheel drive tractors must be parallel to the longitudinal axis of the tractor, alternatively a slight toe-in of the front wheels is permissible up to a maximum of 3 mm as measured at the edges of the wheel rims. To check the exact value of the toe-in setting of four-wheel drive tractors, proceed as follows. 1.

Inflate the front tyres to the specified pressure.

Position the steering at half-lock with a straight-edge along the longitudinal axis of the tractor.

Check that the wheels are parallel to the longitudinal axis of the tractor.

Measure the distance (1) between the front inside edges of the wheel rims, at the height of the wheel hub centers.

Turn both front wheels through 180 ° then measure, again at the height of the wheel hub centers, the distance (2) between the rear inside edges of the wheel rims, checking that this new measurement is equal to or greater than the distance (1) by a maximum of ± 3 mm. The rotation of the wheels through 180 ° is necessary to eliminate the effect on the measurement of any wear of the rims.

1b0o2004061043

24667

If it is necessary to correct the wheel alignment, remove nut (2) and pull the track rod end (1) out of its housing. Slacken off locknut (3) and screw the track rod end (1) in or out to increase or decrease the distance (2, fig. 1). Install the track rod end (1) in its housing and re-check alignment as described in points 4 and 5. After having adjusted the alignment to within the prescribed limits, tighten locknut (3) to the specified torque value of 180 Nm ( 183 kgm) and nut (2) to 100 Nm ( 10.2 kgm).

NOTE: Self-locking nut (2) must be renewed each time it is removed or partially unscrewed.

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Index Steering - 41 Tie rods - 106 Tie rods - Toe in adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Steering - 41 Hydraulic control components - 200

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Steering - 41 Hydraulic control components - 200

TECHNICAL DATA Hydraulic control components Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Power steering control valve Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Power steering system Dynamic description Diagram showing 4WD power steering operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Power steering control valve Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Power steering control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Pressure test for the power steering relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assemble (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassemble (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

DIAGNOSTIC Hydraulic control components Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Steering - Hydraulic control components

Hydraulic control components - Special tools CAUTION The operations described in this section can only be carried out with the ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual. B008

Tool No. 380000281

Description

Alternative previous No. 294056

Roto-glyd seal installer

Pressure Test Tools Tool No.

X X

380000492 380000543 380000545 380000553 380000570 380000599

Description 7/16" UNF male Quick release adaptor Quick release coupler Hose Pressure Gauge 0 - 250 bar (0 - 3625 psi) Tee adaptor, 1/4 ORFS (Internal) x 1/4 ORFS (External) x 7/16 BSP (Internal) Blanking Cap 11/16 ORFS

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Alternative previous No. 297240 291924 292246 293244 297600 -

Steering - Hydraulic control components

Power steering control valve - Torque PARTS TO BE Thread TIGHTENED Power steering spool valve M10X1.5 to support fixing screw Power steering spool valve M8X1 components fixing screws

Tightening torque kgm Nm (lbft) 47 - 55 N·m (34.67 - 40.57 4.8 to 5.6 lb ft) 30 N·m (22.13 lb ft)

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3.0

Steering - Hydraulic control components

Power steering system - Dynamic description Diagram showing 4WD power steering operation

SEZ41CAP1F-3

(1). (2). (3). (4). (5). (6). (7).

: Oil at static rest

: Oil return to tank

: Pump delivery oil

: Intake oil

Power steering lines Steering cylinder assembly Steering motor Kick back check valve Nonâ&#x2C6;&#x2019;return valve Anticavitation storage tank Pump

(8). Filter (9). Return to rear transmission (10). Pressure relief valve (11). Valve seat sleeve (12) (12). Rotating valve (13). Back flow valves

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Steering - Hydraulic control components

SEZ41CAP1F-4

: Oil in delivery line to hydraulic cylinder

: Oil return to tank

: Pump delivery oil

: Intake oil

(A). Right hand turn (B). Steering to the left

OPERATION NOTE: Refer to image 1 if not differently specified. The oil intake is from the rear transmission casing by means of the gear pump (7), passing through a filter (8) and directed to the power steering control valve (3). Turning the steering wheel clockwise (or counterclockwise) causes the steering column to act on the valve (12) that, turning clockwise (or counterclockwise) to the sleeve (11), will send oil through the internal ducts to the hydraulic cylinders ( (2), 1) for steering to the right or left of the tractor. The system is totally hydrostatic without any mechanical connection between the steering wheel and the wheels.

Neutral position ( 1) With the wheels parallel to the direction of tractor travel, as indicated in the drawing, the rotating valve (12) connected to the steering wheel is in the neutral position on the sleeve (11). In this position, which is maintained and guaranteed by the springs ( (11), Hydraulic control components - Exploded view (41.200)) the internal galleries on parts ( (11) and (12), 1) are aligned and direct the oil from the pump (7) to the discharge line (9).

Steering to right * ( 2) When the steering wheel is turned in a clockwise direction, the springs ( (11), Hydraulic control components Exploded view (41.200)) deform, allowing the valve ( (12), 1) to rotate in relation to the sleeve (11). Under these conditions the following occurs: - The internal galleries on parts ( (11) and (12), 1), which were previously communicating in the neutral phase, become misaligned and the oil outflow is interrupted.

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Steering - Hydraulic control components

- The alignment with the same number of ducts, that are connected with the compartments on the rotor in the pump suction phase ( (7), fig. (6)) and in the delivery phase of the steering cylinders (2), allow turning to the right to be carried out.

Steering to the left * When the steering wheel is turned in a counter-clockwise direction, the internal grooves on parts ( (11) and (12), 1) and the delivery to the steering cylinder are inverted, allowing turning to the left to be carried out.

Manual turning to the right * In the event of power steering pump failure or insufficient oil pressure, turning is possible manually. When the steering wheel is turned in a clockwise direction, the power steering control valve ( (3), 1) internal rotor operates as a hand pump, directing the oil to the rod side of the cylinders (2), allowing manual turning to the right.

Manual turning to the left * When the steering wheel is turned in a counter-clockwise direction, the internal power steering control valve rotor operates as a hand pump (as previously described, directing the oil to the cylinder piston side, allowing manual turning to the left.

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Steering - Hydraulic control components

Power steering control valve - Exploded view Hydrostatic steering control valve components

SEZ41CAP1G-1

(1). Dust ring (2). Back flow valve balls (3). Back flow valve pins (4). Control valve body, rotating valve and rotating valve seat sleeve (5). Check valve ball (6). Non-return valve threaded plug (7). O-ring (8). Seal ring support ring (7) (9). Thrust bearing components (10). Spring retaining ring (11) (11). Springs for returning sleeve to neutral position

(12). (13). (14). (15).

Sleeve-rotor drive shaft trim pin Cover retaining screws Non-return valve seat screw Washers

(16). (17). (18). (19). (20). (21). (22).

Cover O-rings Rotor and fixed ring for rotor Shim ring O-ring Rotor drive shaft Damping valve

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Steering - Hydraulic control components

Power steering control valve - Remove To remove the power steering spool valve, proceed as follows: 1.

Detach the cab as indicated in the procedure on page Cab and platform - Remove (90.150).

Detach the cover with the logo from the steering wheel (1), using the tool 380000223 (2) detach the steering wheel itself.

MOIL12APL0019AA

MOIL12APL0020AA

MOIL12APL0021AA

Unscrew the relative retaining bolts and detach the black guard (1) of the instrument cluster.

Unscrew all the relevant screws and detach the guard of the steering wheel column (1) .

Take out the relevant screws and remove the control lever (5) power shuttle.

Take out the relevant screws, disconnect the electrical connections and remove the control panel (2) .

Detach the rear guard (4) of the steering column.

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Steering - Hydraulic control components

Disconnect the piping (1) from the hydrostatic steering spool valve.

MOIL12APL0022AA

MOIL12APL0023AA

Unscrew the screws (1) fixing the hydrostatic steering spool valve to the steering column (2), remove the spool valve itself from outside the cab.

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Steering - Hydraulic control components

Power steering control valve - Install To re-fit the hydrostatic steering spool valve, proceed as follows. 1.

Position and secure the hydrostatic steering spool valve to the steering column.

Connect the piping to the hydrostatic steering spool valve.

Position and secure the rear guard of the steering column.

Position and secure the control panel and connect the electrical connections.

Position and secure the power shuttle control lever.

Position and secure the guard of the steering column.

Position and secure the instrument cluster guard.

Position and secure the steering wheel, fit the cover with the logo on the steering wheel.

10.

Fit the cab back on as indicated in the procedure on page Cab and platform - Install (90.150).

11.

Check the oil level and if necessary top up to the stated quantities Consumables ().

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Steering - Hydraulic control components

Power steering control valve - Pressure test for the power steering relief valve ATTENTION: For the equipment numbers use the conversion table. New number 380000570 380000492 380000545 380000553 380000621 380000281 380000599

Old number 297600 297240 292246 293244 291924 294056 297671

NOTE: There is no relief valve in steering pump and the following pressure test must only be performed as specified below. Failure to observe this precaution may result in severe damage to the hydraulic pump. 1.

Turn the steering wheel onto full right-hand lock.

Turn the starter keyswitch OFF.

Disconnect the right-hand turn feed hose.

Install the T-adapter 380000570 (1) and the quick release fitting 380000492 (4) in the pipe. Close the bottom of the T-adapter with the cap 380000599 or with a standard no. 6 plug with female thread ORFS (11/16) obtained locally (3) .

Connect a pressure gauge with scale from 0 - 250 bar (0.00 - 3625.00 psi) 380000553 (2) , making use of the quick release coupling 380000621 and the hose 380000545 .

Take the engine speed to 1500 RPM to observe the working pressure of the system, or to 2200 RPM for the maximum system pressure. Turn the steering wheel to the left with a pull of approximately 22 N (4.95 lb) (2,25 kgf) and observe the pressure reading.

NOTE: The use of a force greater than 22 N (4.95 lb) (2,25 kgf). at the rim of the steering wheel may lead to slightly inaccurate readings due to the pumping action of the power steering spool valve. The pressure reading must be: 186 bar (2697.00 psi) for all models. If the steering test was satisfactory but pressure readings are away from specification the relief valve in the steering motor must be adjusted 7.

If the system pressure is not to specification proceed to relief valve adjustment.

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WLAPL4S41C103A

Steering - Hydraulic control components

Differential pressure Differential pressure is the difference in pressure between the supply and sump ports on the power steering spool valve. The measured pressure (pressure gauge) is given by the calibration value of the relief valve plus the counterpressure in the system. The system counter-pressure must be approximately 16 bar (232.00 psi) for all of the models. The oil flow out of the power steering spool valve returns to the pump body to be distributed to the low pressure and/or lubrication circuits. The pressure of the oil returning from the power steering spool valve is regulated to 16 bar (232.00 psi) , by the low pressure regulating valve, to 2100 RPM While the pressure is regulated, the excess oil in the low pressure circuit flows through the regulation valve and from here to an adjacent relief valve of the lubrication circuit, that limits the pressure of the oil in the lubrication circuit between 2.9 - 3.7 bar (42.05 - 53.65 psi) .

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Steering - Hydraulic control components

Steering Motor Relief Valve Adjustment

WLAPL4S41C101G

(1) Plug (2) Steering drive shaft (3) Relief valve (4) Power steering spool valve outlet hose made locally (5) Tractor tubes to steering cylinder (6) Hose made locally to connect the pump delivery to the power steering spool valve

(7) Pressure gauge at least 0 - 350 bar (0.00 - 5075.00 psi) (0-5000 lbf.in2) (8) Articulated T-fitting size 8 ORS (9) Articulated T-fitting size 10 ORS (10) Pressure gauge at least 0 - 350 bar (0.00 - 5075.00 psi) (0-500 lbf.in2) (11) Blanking plug size 6 ORS (12) Spring (13) Calibration register

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Steering - Hydraulic control components

Relief Valve Adjustment - All models NOTE: Refer to Figure 2 NOTE: To adjust the steering system relief valve it is necessary to remove the power steering spool valve from the steering bracket, to gain access to the hexagon headed adjusting screw. 1.

Disconnect the power steering spool valve from the bracket of the steering system, and remove it from the tractor.

Fabricate suitable hoses locally to connect to the tractor delivery and return pipes. Connect the hoses and T-fittings obtained locally and install the pressure gauges. Start the engine and leave it running between 1450 - 1500 RPM and run the tractor until the transmission oil reaches the normal working temperature of approximately 68 Â°C (154.40 Â°F) .

With the engine running, turn the power steering spool valve shaft to obtain full lock. The pressure indicated by the pressure gauge on the point (A) must be 186 bar (2697.00 psi) . The pressure indicated by the pressure gauge on the point (B) must be in the order of 16 bar (232.00 psi) .

To determine the actual pressure (differential) subtract the pressure gauge reading (B) from that of the pressure gauge (A). To come within the specifications, the differential pressure must be: 186 bar (2697.00 psi) for the pressure gauge (A), minus 16 bar (232.00 psi) for the pressure gauge (B)= 170 bar (2465.00 psi) for all of the models.

If the pressure readings are not correct, turn the adjuster screw (item (13) ), 10 using an 8 mm (0.3150 in) hexagon key. Half a turn on the adjuster screw equates to approximately 13.8 bar (200.10 psi) .

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Steering - Hydraulic control components

Power steering control valve - Assemble (Steering Motor) Prior operation: Power steering control valve - Disassemble (Steering Motor) (41.200) 1.

Assemble inner and outer sleeves so that the leaf spring slots align. Install the drive pin.

60-41-010

60-41-012

60-41-009_499

Install the leaf springs and push fully into position.

Install leaf spring retainer, and bearing.

NOTE: The inner bearing race must be positioned with the chamfer side facing the spool.

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Steering - Hydraulic control components

Apply a light coating of hydraulic oil onto the sleeve and insert into the steering motor body. Coat the `O' ring and back-up ring, with hydraulic fluid and position them onto the seal installer guide.

NOTE: Use special tool No. 380000281 to install oil seal type roto-glyd.

60-41-013

60-41-014

60-41-015

60-41-005_500

Position the seal guide tool into the sleeve and push down with a twisting action. Remove tools once the seal has seated.

With the seal installed in the motor body refit control valve.

NOTE: Ensure that the Drive is in a horizontal position to aid re-assembly.

Once the control valve is seated correctly refit the check and suction valves (2WD only). Screw the check valve down to just below the surface of the housing.

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Steering - Hydraulic control components

Refit the `O' Ring and place the end plate in position.

60-41-016

60-41-004_501

Metering Unit Reassembly 9.

10.

To aid reassembly install the control valve into the housing so that the drive pin is perpendicular to the front face of the housing. Install drive link into the steering motor body, ensuring that the link engages correctly over the drive pin.

Assemble the metering unit rotor and stator and install new lightly greased `O' rings to either side of the stator. Assemble the rotor and stator onto the drive link.

60-41-003_502

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Steering - Hydraulic control components

11.

12.

Install the end plate and bolts, ensure the pin bolt (1) is fitted in position `7'. Tighten the bolts in two steps, first to 10.8 Nm (8.0 lb ft) and then to 28.4 Nm (20.9 lb ft) in sequence as shown.

1b0o2004061083

60-41-006_503

Install the relief valve assembly, items (1), (2) and (3), leaving the plug, item (4) out until after the relief valve has been adjusted. Check to ensure the motor turns freely without binding.

NOTICE: The relief valve must be set to the correct pressure setting after the motor has been re-assembled. Follow the correct procedure as Steering circuit relief valve - Pressure setting (41.200).

Next operation: Power steering control valve - Install (Steering Motor) (41.200)

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Steering - Hydraulic control components

Power steering control valve - Visual inspection 1.

Wash all parts in a suitable solvent to remove any foreign particles and dry with a clean lint free cloth or compressed air.

Inspect valve sleeves for, damage or wear. Minor burrs or scratches can be removed with a fine abrasive. Ensure all parts are thoroughly cleaned prior to re-assembly.

Check leaf springs for damage. Replace if necessary.

Discard all `O' ring seals and replace with new seals on re-assembly.

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Steering - Hydraulic control components

Power steering control valve - Disassemble (Steering Motor) Prior operation: Power steering control valve - Remove (Steering Motor) (41.200) 1.

With the steering motor connectors removed note position of the non return valve. Hold the steering motor securely in a vice using a tube connector as shown in, Figure 1. Remove the end plate bolts, end plate and `O' ring.

NOTE: The position of the pin bolt must remain the same on re-assembly.

60-41-002

60-41-003

60-41-004

Remove metering unit, valve plate and `O' ring seals, note mating surfaces for correct re-assembly.

Lift out rotor drive-shaft.

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Steering - Hydraulic control components

Unscrew the check valve retainer and shake out the check and suction valves (2WD only).

60-41-005

60-41-006

60-41-007

60-41-008

Remove the relief valve assembly.

NOTICE: The relief valve must be set to the correct pressure setting on re-assembly.

Remove the inner and outer valve sleeves, bearings and thrust washer.

NOTE: When removing spool and sleeve ensure drive pin is in a horizontal position so that it cannot fall into an internal gallery and make removal difficult.

Once spool is disassembled from the body ensure oil seal is removed.

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Steering - Hydraulic control components

Remove the control valve spool and sleeve.

NOTICE: Upon re-assembly ensure washer (1) is installed with chamfer towards the valve sleeve.

60-41-009

60-41-010

Remove centering springs. Remove drive pin. Push inner sleeve from outer sleeve. Remove `O' ring and back-up ring.

NOTE: Arrangement of the leaves must remain the same upon re-assembly.

Next operation: Power steering control valve - Visual inspection (41.200) Power steering control valve - Assemble (Steering Motor) (41.200)

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Steering - Hydraulic control components

Hydraulic control components - Troubleshooting Problem Hard steering.

Possible Cause Hydraulic pump faulty. Non-return valve (5) held open by foreign bodies or due to absence of ball. Pressure relief valve (22) incorrectly set. Pressure relief valve (22) jammed or held open by foreign bodies. Steering column has become stiff on its bushing due to rusting, seizing, etc. Excessive steering wheel Excessive play between the steering colplay. umn and the coupling with the rotating valve ( (12), figure 2 in Power steering system - Dynamic description Diagram showing 4WD power steering operation (41.200) ). Excessive play in the coupling between the shaft ( (21), Hydraulic control components - Exploded view (41.200)) and the trim pin (12). Excessive play in the splined coupling between the shaft (21) and the rotor (18). Combination of excessive play as described in the previous points. Leaf springs (11) damaged or fatigued. The steering wheel turns Inadequate control cylinder seal. normally, but the steering is: a. Low. b. Null. Cylinder rod broken Rotor drive shaft (21) or pin (12) broken. With the engine stopped, Excessive wear between rotor and fixed the steering wheel can be ring . turned without turning the wheels. Non-return valve damaged. Incorrect synchronization of hydrostatic Steering wheel jolts, uncontrollable steering, steering. wheels turning in the opposite direction to that desired. Pipes to cylinder inverted. Hydraulic cylinder piston seal worn. The wheels do not maintain the desired alignment and steering must be continually corrected with the steering wheel. Back flow valve ( (2), Hydraulic control components - Exploded view (41.200)) held open by foreign bodies or damaged. Mechanical wear of control valve.

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Correction Repair the pump. Eliminate foreign bodies and clean filter; put a new ball into the seat (if missing). Calibrate the valve correctly. Eliminate foreign bodies and clean the filter. Eliminate the causes. Replace the worn parts.

Replace the worn parts.

Replace the worn parts. Replace the excessively worn parts. Replace springs. Replace seal.

Replace the damaged part. Replace the damaged part. Replace the worn parts.

Replace control valve assy. Synchronize correctly.

Correct the connections. Replace seal.

Eliminate foreign bodies and clean filter or replace the control valve. Replace control valve assy

Steering - Hydraulic control components

Problem Possible Cause Leaf springs (11), for sleeve (4) return to Neutral phase of power neutral position, damaged or fatigued. steering unobtainable. During manual control, operation is normal; when stopping man al control the steering wheel tends to move on its own, or remain stationary, but steering continues slowly in the direction that was initially selected (â&#x20AC;?mopedâ&#x20AC;? effect), therefore steering must be continually corrected with the steering wheel. Sleeve and rotating valve (4) locked in delivery position because of the presence of foreign bodies. Sleeve (4) crushed on the rotating valve due to excessive pressure.

Correction Replace the leaf springs assembly.

Eliminate foreign bodies and clean the filter.

Check the pressure relief valve calibration ( (22), Hydraulic control components Exploded view (41.200)). Insufficient pressure. Check the hydraulic pump and the pressure Difficulty in steering in relief valve calibration ( (22), Hydraulic general, or only in one control components - Exploded view direction. (41.200)). Excessive leakage inside the control valve. Replace control valve assy. Vibrations on front wheels Air pockets in the hydraulic cylinder. Bleed the air and eliminate the causes of (shimmy). possible infiltration. Wear on mechanical joints on steering Replace the worn parts. rods. Back flow valve (2) held open by foreign Eliminate foreign bodies and clean filter or bodies or damaged. replace the control valve.

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Index Steering - 41 Hydraulic control components - 200 Hydraulic control components - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic control components - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Power steering control valve - Assemble (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Power steering control valve - Disassemble (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Power steering control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Power steering control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Power steering control valve - Pressure test for the power steering relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Power steering control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Power steering control valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Power steering control valve - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Power steering system - Dynamic description Diagram showing 4WD power steering operation . . . . . . . . . . . . . . 5

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Steering - 41 Cylinders - 216

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Steering - 41 Cylinders - 216

SERVICE Steering cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Steering - Cylinders

Steering cylinder - Remove To remove the steering cylinder from the front axle, proceed as follows: 1.

Removing the cylinder from a front axle assembly removed from the tractor and positioned on a stand, see sect. Powered front axle - Remove (25.100)

Remove the nuts (1) locking steering heads on stub axles.

MOIL12APL0014AA

MOIL12APL0015AA

MOIL12APL0016AA

Using a puller, extract the steering heads from the seats on the stub axle housings.

Extract the steering heads (1) governing the stub axles, on both sides. On the left-hand side, loosen the locknut (2) for adjusting toe-in, then fully unscrew the head.

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Steering - Cylinders

Take out the power steering pipe bracket retaining bolt (1), remove the related unions and extract them.

MOIL12APL0017AA

MOIL12APL0018AA

Take out the fixing screws (1) and remove the cylinder.

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Steering - Cylinders

Steering cylinder - Install To assemble, proceed as follows: 1.

Fit the cylinder on the axle and secure it with the bolts.

Mount the power steering pipes on the cylinder and secure them with the relevant bracket.

Mount the steering heads on the cylinder.

Secure the steering heads on the fuse boxes of the wheel hubs and lock them with the fixing nuts.

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Index Steering - 41 Cylinders - 216 Steering cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Steering cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47538922 29/05/2013 EN

SERVICE MANUAL Electrical systems

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Electrical systems - 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

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Electrical systems - 55 Electrical system - 000

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Electrical systems - 55 Electrical system - 000

FUNCTIONAL DATA Electrical system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Static description Circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Electrical system

Electrical system - Dynamic description STARTING SYSTEM (DESCRIPTION AND OPERATION) All systems consist of an ignition key switch, heavy-duty wiring, a starter motor with solenoid, a starter relay and a clutch pedal switch. These are the components of the circuit used on these machines. This tractor is equipped with a semi Powershift transmission with a creeper unit, that increases the number of gears available from 16 forward and 16 reverse to 32 forward and 32 reverse. Only one starter motor available with rated power of 3.2 kW. This motor has four poles, four brushes with integrated electromagnet and positive mesh engagement control. The electromagnet consists of two parallel-connected windings. The low resistance intake winding is grounded via the engine, whilst the high resistance hold winding is grounded via the electromagnet body. If the starter switch is closed, with the clutch pedal pressed and the shuttle lever in neutral, the coils of the solenoid are energised and the moving core is magnetically drawn into the magnet. This movement, transmitted by an adjustable joint mechanism, makes the driving pinion engage the flywheel rim gear.

When the pinion makes contact with the rim gear, the plunger closes a series of contacts in order to directly power-up all four field coils, thereby supplying full power to the starter motor. At this stage, one end of the intake coil is connected to the positive battery pole through the starter switch, whilst the other end is connected to the positive battery pole through the solenoid valve contacts. In this manner the intake coil is bypassed, without absorbing power, and the hold coil exclusively maintains the electromagnet plunger in position. The starter motor includes a series of contacts and a two-part electromagnet plunger that totally closes the contacts, even if the pinion teeth are not perfectly in line with those of the crown wheel. When this happens, a clutch spring compresses the pinion, forcing it to engage completely as soon as the starter motor begins to turn over. When the key-switch is released, power to the electromagnet and motor is cut off. The electromagnet return spring, acting on the adjustable joint mechanism, frees the driving pinion from the gear and reopens the solenoid valve contacts. A roller-type clutch mechanism is incorporated in the driving pinion unit. This prevents the pinion from over speeding if it remains engaged in the flywheel crown wheel after the engine has started.

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Electrical systems - Electrical system

Electrical system - Static description Circuit components ATTENTION: THE CHAPTERS DEALING WITH ELECTRICAL COMPONENTS REFER TO THE STATUS OF THESE PARTS (FOR EXAMPLE: SWITCH NORMALLY OPEN OR CLOSED, SOLENOID VALVES NORMALLY OPEN OR CLOSED AND SENSORS OF VARIOUS TYPES.). THESE REFERENCES TO COMPONENT STATUSES ARE ALWAYS TO BE CONSIDERED WITH THE MACHINE STATIONARY (COMPONENT DISCONNECTED FROM THE CIRCUIT).

CIRCUIT PROTECTION DEVICES Circuit protection devices are used to protect wiring and components from excessive current. Three different types of protection are fitted in tractors. Two of them (fuses and fusible links) are currently used, while circuit breakers are no longer used.

SEZ55CAP9A-55

SEZ55CAP9A-5

SEZ55CAP9A-6

FUSES, FUSIBLE LINKS Fuses and fusible links protect circuits with thin pieces of metal and wire which heat up and melt to open up the circuit when too much current flows through them. Fuses are used to protect the circuit from overload. This can occur in the event of a short circuit or by connecting equipment which demands a 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 limited current. If the specified current is exceeded then the metal conductor will overheat, causing it to melt and break. This will in turn cause an open circuit. The rating of the fuse relates to the current that the fuse can carry continuously. If a fuse blows, it must be replaced with a fuse of the correct rating, and if it blows again, then the cause must be investigated.

FUSE LINKS A fuse link is a wire that acts like a fuse, breaking down and causing an open circuit when the current that passes through it exceeds a certain amperage. For primary fuse protection the main supplies from the starter solenoid are fitted with fuse links.

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Electrical systems - Electrical system

CIRCUIT CONTROL DEVICES Some of the components in a circuit are used to interrupt and direct current flow either through an action of the operator or automatically. The current interrupters you are probably most familiar with are switches.

SEZ55CAP9A-56

SEZ55CAP9A-57

SEZ55CAP9A-58

VAR Switches are a vital part of an electric circuit, providing a method of controlling the circuit itself. One switch can control a number of different circuits at the same time. This is achieved by having several separate connections and/or multi--connector switches (several switch â&#x20AC;&#x2122;positionsâ&#x20AC;&#x2122;). There are several types of switch, and they may incorporate a warning light. Switches can be as simple as that used to turn on an implement lamp or as complex as the ones used to operate the starting and lighting systems. Checking the operation of switches is usually just a matter of testing for power going into the switch and for power leaving the switch at the appropriate contacts when the switch is operated. One of the most common type of switches is the pressure switch (image), a switch turned on or off by the pressure of a fluid. An example of this type of switch is the engine oil pressure switch, a simple on/off device that opens (or closes) when oil pressure rises above 0.7 bar (10.15 psi).

FLASHERS Flashers work automatically to interrupt and connect the flow of current. Their operation is similar to that of the circuit breaker described earlier. In the flasher, a heating element heats a bimetallic strip, that bends, breaking the contact with the power supply. When it cools, the bimetallic strip once again makes contact and the process begins again.

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Electrical systems - Electrical system

DIODES Some components use a semiconductor material instead of moving parts to direct current. Diodes for example, allow current flow in one direction only. They are essential in converting the alternating current that an alternator produces to the direct current that the tractor electrical system components use.

SEZ55CAP9A-7

SEZ55CAP9A-59

SEZ55CAP9A-60

RESISTANCE DEVICES A number of electrical components alter or make use of electricity through their resistance to current flow. Resistors are components which are generally used to regulate the supply of voltage and current to other electrical components. In some cases, the purpose of resistance in an electrical circuit is to provide light or heat. Lamps and cigar lighters are examples. Lamps convert electricity into light, and cigar lighters convert it into heat. Both lamps and lighters make use of the same physical principle, that is Ohms Law.

POTENTIOMETERS Potentiometers are variable resistors which are dependant on mechanical movement, i.e. Lateral float movement, to vary the resistance of the component and therefore alter the output voltage. In order to verify the correct operation of a potentiometer, the resistance should be measured at the minimum and maximum positions and a smooth and continuous change of resistance should be observed between. As the resistance varies with temperature, the test specifications are usually given at 20 Â°C (68.00 Â°F).

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Electrical systems - Electrical system

ELECTROMAGNETIC DEVICES In general, they use the magnetic field created by flowing current to move metal parts within the components. The relay is an electromagnetic switch that uses a small amount of current to switch a larger amount on and off. 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 (see 10). 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. Relays are basically electrically operated switches. They are used to switch a circuit on/off in similar way to a manual switch. Two circuits are connected to the relay: • A work circuit, which is opened and closed by the relay and provides the supply for the equipment to be operated, i.e., bulbs, solenoids, etc. • A control circuit, that is opened and closed by manual switches and used to actuate 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. A switch--relay system has two main advantages over a simple switch: • The current that flows through the switch is not the same as the current required by the equipment to be operated, but is usually smaller: 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 minimise voltage drop. There are several types of relays. They can be normally open or normally closed. They may have internal electronic circuits to give special operating features. For example, they can turn the switch on/off at timed intervals (flasher relay), be sensitive to current, temperature, etc. The relay cover usually gives information about the features of the relay. On the relay cover there are usually 4 or 5 terminal markings: • 30: input terminal direct from battery positive, normally live. • 85: winding output terminal, usually to ground. • 86: winding input terminal. • 87: output terminal for normally closed contact. • 87a: output terminal for normally open contact. Brown relays are normally open relays, blue ones are normally closed.

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SEZ55CAP9A-8

SEZ55CAP9A-9

Electrical systems - Electrical system

SOLENOID VALVES The solenoid valves ( 12) work in much the same way as relays, except that the iron core is not fixed in place. As a result, the windings in the control circuit cause the iron core to move. In the starting system, for example, the movement of this core is used to send large amounts of current to the starter motor. A solenoid is basically a winding around an iron core. In the centre of the core there is a plunger which is free to move through the core. When an electrical current passes through the winding an electro--magnetic force is produced which causes the plunger to move through the core. If the current is switched off, the magnetic force is stopped and the plunger is returned by a spring. The solenoid plunger may have different uses: the most common are moving a hydraulic spool or a mechanical lever. The use of solenoids to control hydraulic pressure instead of the hydraulic valves is highly recommended wherever there is a long distance between the control panel and the valve (more than 10 m (32.81 ft)) or a fast action is required. A coil should: • Be non--sensitive to vibrations; • Be silent in operation • Have large frequency of activation (30--35 times per second) • It should be possible to fit it in any position. • Be insulated, in order to function correctly for a wide range of temperatures ( -40 - 85 °C (-40.00 - 185.00 °F)), and with high humidity conditions. The MOST COMMON FAULTS that can occur are: • Winding shorted: if a section of the winding allows the current to pass directly from positive (+) to negative (-) terminals without passing through the winding, this will cause the relevant circuit fuse to blow. • Broken winding: causing an open circuit, it will not allow the current to pass through the winding, so the solenoid will not operate. • Seized plunger (and/or connected components): the solenoid will only move the plunger if all components are free to move.

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SEZ55CAP9A-10

Electrical systems - Electrical system

PROPORTIONAL SOLENOID VALVES (PWM) 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 V. The processors 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 (see 14). The ratio between the ON time and the cycle time is called duty cycle and is stated as a percentage of one complete cycle.

Please refer to Fig. 14, diagrams (1) to (3) show the normal operating range of a modulating valve ( PWM), and diagram (4) shows the initial 12 V 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 (C) 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 V 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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SEZ55CAP9A-61

SEZ55CAP9A-11

Electrical systems - Electrical system

SENSORS A sensor is the primary component of a measurement chain that converts the input variable (temperature, capacitance, reluctance) into a signal suitable for measurement. The relationship between the input variable and the measured signal is a characteristic of the sensor. In the above mentioned measurement chain the signal is filtered and treated in order to adapt it to its use. It consists of three elements: the sensor itself; the converter, which converts the output signal from the sensor (in most of the cases into an electric signal); and the conditioner, which transforms the output signal from the converter in the most suitable form. Generally the term sensor indicates the entire measurement chain.

TEMPERATURE SENSORS Generally based on a simple circuit with a thermistor. A thermistor is a resistor that changes its resistance according to the temperature. There are two groups of thermistors: NTC (negative temperature coefficient) and PTC (positive temperature coefficient). In the first case the higher the temperature, the lower is the resistance, and for the PTC the higher the temperature, the higher the resistance. The NTC are often used as sensors to indicate temperature change in fluids, such as the engine coolant fluid. An example of these type of senders is the coolant temperature sender. The changes in its resistance (which varies with temperature) are relayed to the Instrument Cluster, which operates the gauge and the warning indicators accordingly.

SEZ55CAP9A-62

SEZ55CAP9A-12

SEZ55CAP9A-63

PRESSURE SENDER A pressure sender receives a supply signal and it varies it according to the (oil) pressure. An example is the oil pressure sender, which receives a 5 V signal and varies it according to the oil pressure. The Instrument Cluster keeps track of these variations and changes its readouts and warnings accordingly.

SPEED SENSOR The speed sensor is typically a reluctance sensor. An example is the axle speed sensor, which is fitted into the transmission and gets pulses off the gears, counting the gear teeth. The sensor uses a pickup coil. The action of the gear close to the pickup creates pulses which are relayed to the controller. The controller converts the frequency of the pulses into ground speed. Possible failures are due to vibration, open circuits.

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Electrical systems - Electrical system

FLUID LEVEL SENDER It operates by varying resistance through the movement of a float. An example is the fuel level sender.

SEZ55CAP9A-13

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Index Electrical systems - 55 Electrical system - 000 Electrical system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical system - Static description Circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Harnesses and connectors - 100

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Wire harnesses Overview HOW TO USE THE WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wiring standard COLOR CODE OF THE WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Electrical schema index COMPONENTS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical schema index DESCRIPTION INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Electrical schematic frame 01 BATTERY, ALTERNATOR AND POWER SUPPLY UNIT (with battery isolator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE

Electrical schematic frame 01 BATTERY, ALTERNATOR AND POWER SUPPLY UNIT (with and without battery isolator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 T5.95 ElectroCommand NA, T5.105 ElectroCommand NA, T5.115 ElectroCommand NA

Electrical schematic frame 02 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Electrical schematic frame 03 ELECTRONIC LIFT (EDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Electrical schematic frame 04 POWER TAKE OFF, DIFFERENTIAL LOCK, 4 WHEEL DRIVE . . . . . . . 48 Electrical schematic frame 05 AIR CONDITIONED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Electrical schematic frame 06 WORKLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE

Electrical schematic frame 06 WORK LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 T5.95 ElectroCommand NA, T5.105 ElectroCommand NA, T5.115 ElectroCommand NA

Electrical schematic frame 07 ROAD LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE

Electrical schematic frame 07 ROAD LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 T5.95 ElectroCommand NA, T5.105 ElectroCommand NA, T5.115 ElectroCommand NA

Electrical schematic frame 08 WINDSCREEN WIPERS AND ROTATING BEACONS . . . . . . . . . . . . . . 60 Electrical schematic frame 09 SERVICE SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Electrical schematic frame 10 BRAKE PEDALS, LICENSE PLATE LIGHT AND 3RD REMOTE VALVE 64 Electrical schematic frame 11 CAN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Electrical schematic frame 12 INTERNAL ISOBUS LINE TO CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Electrical schematic frame 13 EXTERNAL ISOBUS LINE TO CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Electrical schematic frame 14 TRANSMISSION CONTROL 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Electrical schematic frame 15 TRANSMISSION CONTROL 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Electrical schematic frame 16 INSTRUMENT PANEL CONTROL UNIT 1 . . . . . . . . . . . . . . . . . . . . . . . . . 76 Electrical schematic frame 17 INSTRUMENT PANEL CONTROL UNIT 2 . . . . . . . . . . . . . . . . . . . . . . . . . 78 Electrical schematic frame 18 ENGINE CONTROLS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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Electrical schematic frame 19 ENGINE CONTROLS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Electrical schematic frame 20 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Electrical schematic frame 21 ROOF FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Electrical schematic frame 22 FLASHER UNIT, LIGHTS CONTROL SWITCH AND RADIO . . . . . . . . . 88 Electrical schematic frame 23 FRONT-END LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Electrical schematic frame 24 ITALIAN TRAILER BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Electrical schema ADIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Electrical schema CCU CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Overview BUS protocol connections and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Wire connectors Component Diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Component diagram 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Component diagram 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Component diagram 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Component diagram 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Component diagram 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Component diagram 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Component diagram 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Component diagram 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Component diagram 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Component diagram 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 Component diagram 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Component diagram 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 Component diagram 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Component diagram 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Component diagram 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 Component diagram 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Component diagram 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Component diagram 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 Component diagram 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Component diagram 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Component diagram 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Component diagram 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 Component diagram 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Component diagram 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 Component diagram 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Component diagram 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 Component diagram 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 Component diagram 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 Component diagram 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 Component diagram 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

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Component diagram 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Component diagram 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309 Component diagram 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Component diagram 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Component diagram 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 Component diagram 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 Component diagram 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 Component diagram 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 Component diagram 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366 Component diagram 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 Component diagram 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 Component diagram 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372 Component diagram 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 Component diagram 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376 Component diagram 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382 Component diagram 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383 Component diagram 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 Component diagram 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 Component diagram 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394 Component diagram 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401 Component diagram 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402 Component diagram 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 Component diagram 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 Component diagram 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 Component diagram 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418 Component diagram 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 Component diagram 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438 Component diagram 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 Component diagram 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

Fuse and relay box Static description FUSE BOX AND MAIN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE

Static description FUSE BOX AND MAIN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 T5.95 ElectroCommand NA, T5.105 ElectroCommand NA, T5.115 ElectroCommand NA

Static description FUSE BOX AND RELAY FOR ROOF EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 457

SERVICE Wire harnesses Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462 Rewire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464 Measure Digital multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465 Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468

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Wire harnesses - Overview HOW TO USE THE WIRING DIAGRAMS HOW TO USE THE WIRING DIAGRAMS The wiring diagrams are included in each version (type of transmission) and they have been drawn up in a functional manner. This means that the complete wiring diagram of a certain tractor version has been drawn over a number of pages, each one of which includes the portion of circuit related to one or more functions (e.g. “Front and rear electronic lift”; “Direction indicators and hazard lights”, etc.). All these pages, if joined together would make a complete diagram of the tractor for each version.

SEZ55CAP6F-11

There are a number of guides to help assist in reading and understanding the wiring diagrams. 1. The wiring diagrams (2) are located on the right- hand pages; the titles and keys (1) are on the left- hand pages. The title defines the function to which the diagram refers, the key indicates all the components on that specific page of the diagram. 2. The components and connectors are identified by an abbreviation composed of an alphabetical portion and a numerical portion: - the alphabetical portion indicates the type of component. - the numerical portion is a progressive number.

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3.. On each connecting wire there is an abbreviation composed as follows: (1)- Cable identification (if printed); (2)- Wire main color; (3)- Color of the striping along the wire; (4)- Wire section in mm2.

SEZ55CAP6A-5

SEZ55CAP6A-12

SEZ55CAP6A-6

SEZ55CAP6A-13

4.. To be able to follow the circuit in its entirety, each wire continuing onto a different page of the diagram ends with an arrow and a reference to the page on which it continues or from which it comes. This reference is composed of an abbreviation made up of a number indicating the sheet of the diagram on which the wire continues and one or more letters to indicate the wire on the page being referred to. The following example gives a reference between diagram 1 (ref. (1)), for the cab version and diagram 3 (ref. (2)) ( 3, 4).

5.. The termination of the wire on a component is indicated with the symbol of the connection (see the key of symbols used on the diagrams) and the number of the pin on which the wire is connected (ref. (1)) ( 5).

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CONNECTOR CODE READING The connections on the wiring diagrams are indicated as in the following example. In this example the abbreviation (1) indicates the number of the key of the connection while the second abbreviation (2) indicates the number of the pin of the same connection.

SEZ55CAP6A-7

ELECTRICAL CIRCUIT COMPONENTS Alternator Battery Block of nodes or welds Condenser Connector Diode Audio devices Fuse Switches Lamp and LED Ground Control unit module Engine Relay Resistance Weld or node Transmitter sensor Solenoid Battery cut-off Group ofâ&#x20AC;¦ (e.g. shuttle lever)

COMPONENT CODE G-001 G-001 W-001 C-001 X-001 V-001 H-001 F-001 S-001 E-001 GND-001 A-001 M-001 K-001 R-001 SP-001 B-001 Y-001 Q-001 Z-001

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Wire harnesses - Wiring standard COLOR CODE OF THE WIRING BK BLACK GN GREEN YE YELLOW BL BLUE BR BROWN RD RED GY GRAY OR ORANGE VT VIOLET WH WHITE PK PINK TN TAN TQ TORQUESE LG LIGHT GREEN WHERE TWO COLORS ARE SPECIFIED FIRST COLOUR INDICATES BASE COLOUR, SECOND COLOUR INDICATES STRAIGHT STRIPE

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Wire harnesses - Electrical schema index COMPONENTS INDEX COMPONENT A-001

A-002

CONNECTIONS DESCRIPTION X-533, X-003, Power distribution unit ( PDU ) X-004, X-005, X-006, X-007, X-014, X-049, X-434 X-008 X-009 Battery isolator control module ( BDS )

A-003

X-110, X-120, X-130, X-140

Cab relay and fuse panel

A-004

X-150

Fuse and relay roof panel

A-005

X-450 (CH1), X-460 (CH2), X-377 (CH3)

Analogue/digital instruments ( ADIC)

A-006

X-937, X-939

Engine Control Unit ECU

A-007

X-090

Flasher Unit

A-008

X-200, X-210, X-220, X-230, X-240

Central control unit ( CCU)

A-009

X-938

Glowplug control unit

A-010

X-045

Air-conditioning control unit

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WIRING DIAGRAM Wire harnesses - Electrical schematic frame 01 (55.100)

Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

COMPONENT A-011

CONNECTIONS DESCRIPTION X-326 Electronic lift mouse

WIRING DIAGRAM Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical Electronic lift LED panel schematic frame 03 (55.100) Wire harnesses - Electrical Gear lever pushbuttons schematic frame 15 (55.100) Front windscreen wiper timer module Wire harnesses - Electrical schematic frame 08 (55.100) Joystick Wire harnesses - Electrical schematic frame 11 (55.100) Electro-hydraulic remote valve 1 control ( Wire harnesses - Electrical schematic frame 11 (55.100) EHR1) Electro-hydraulic remote valve 2 control ( Wire harnesses - Electrical schematic frame 11 (55.100) EHR2) Wire harnesses - Electrical ISOBUS controller ( TECU) schematic frame 12 (55.100) Wire harnesses - Electrical ISOBUS line connector for implement schematic frame 12 (55.100) control display Arms position sensor Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical Lift potentiometer panel schematic frame 03 (55.100) Wire harnesses - Electrical Electronic lift left draft sensor schematic frame 03 (55.100) Wire harnesses - Electrical Electronic lift right draft sensor schematic frame 03 (55.100) Wire harnesses - Electrical Speed sensor PTO schematic frame 04 (55.100) Termostato antibrina Wire harnesses - Electrical schematic frame 05 (55.100) Transmission temperature sensor Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical Speed sensor schematic frame 14 (55.100) Wire harnesses - Electrical Clutch pedal potentiometer schematic frame 15 (55.100) Hand throttle potentiometer Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical Fuel Level Sensor schematic frame 17 (55.100) Wire harnesses - Electrical Water in fuel sensor schematic frame 18 (55.100) Air temperature sensor Wire harnesses - Electrical schematic frame 18 (55.100) Lambda sensor Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical Particulate pre-filter exhaust gas schematic frame 18 (55.100) temperature sensor ( DPF ) Pre-catalyser exhaust gas temperature Wire harnesses - Electrical sensor schematic frame 18 (55.100) Pre/post DPF pressure difference sensor Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical Air pressure/temperature sensor schematic frame 19 (55.100) Phase sensor Wire harnesses - Electrical schematic frame 19 (55.100) Exhaust gas pressure sensor on the Wire harnesses - Electrical manifold schematic frame 19 (55.100)

A-012

X-534

A-014

X-320

Aâ&#x20AC;&#x201C;017

X-048

A-018

X-173

A-019

X-396

A-020

X-397

A-021

X-204

A-022

X-203

B-001

X-328

B-002

X-327

B-003

X-331

B-004

X-332

B-005

X-341

B-006

X-044

B-008

X-316

B-009

X-309

B-010

X-322

B-011

X-324

B-012

X-354

B-013

X-950

B-014

X-942

B-015

X-943

B-016

X-945

B-017

X-946

B-018

X-947

B-019

X-961

B-020

X-962

B-021

X-963

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COMPONENT B-022

CONNECTIONS DESCRIPTION X-965 Crankshaft Speed Sensor

B-023

X-967

Rail pressure sensor

B-024

X-968

B-025

X-969

Check whether the implement specifications are suited to the machine. Coolant temperature sensor

B-026

X-970

Fuel volume sensor

B-027

X-971

B-029

X-333

Exhaust gas temperature sensor on manifold Radar

B-030

X-194

B-031

X-195

1-4 / 5-8 ranges synchroniser position sensor Shuttle synchronizer position sensor

B-032

X-196

Transmission oil pressure sensor

B-033

X-178

Trailer brake air pressure sensor

E-001

X-040

Air conditioning panel illumination

E-002

Interior light

E-003

X-051, X-052, X-053 X-306

E-004

X-055

Rear right work light on roof

E-005

X-307

Rear left work light on roof - optional

E-006

X-056

Rear left work light on roof

E-007

X-057

Front right work light on roof

E-008

X-058

Front left work light on roof

E-009

X-059

Right work light on handrail

E-010

X-060

Left work light on handrail

E-011

X-054

Spot light

E-012

X-017

Left swivel lamp

E-013

X-018

Right swivel lamp

E-014

X-019

Front LH headlamp

E-015

X-020

Front RH headlamp

E-016

X-021

Front left direction indicator on handrail

E-018

X-023

Left rear lamp

E-019

X-022

Front right direction indicator on handrail

Rear right work light on roof - optional

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WIRING DIAGRAM Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100)

Electrical systems - Harnesses and connectors

COMPONENT E-020

CONNECTIONS DESCRIPTION X-024 Right rear lamp

E-021

X-096

Left license plate light on roof

E-022

X-097

Right license plate light on roof

E-025

X-386

E-026

X-021A

E-027

X-022A

E-028

X-387

Rear left direction indicator on cab roof (optional) Front left direction indicator on cab roof (optional) Front right direction indicator on cab roof (optional) Rear right direction indicator on cab roof

E-034

X-171, X-172

Electronic remote valve tail light bulb

F-001 F-002 F-003 F-004 F-005

Left fan speed third power [+ 12 V F-058 200 A] Power CN1A CCU [+ 12 V F-061 - 10 A] Dipped beam power [+ 12 V F-058 - 200 A] Fuel heating power [+ 12 V F-058 - 200 A]

F-006

" shuttle" lever and gear change power [+ 12 V 15/54 Key] " C&D" clutch power [+ 12 V 15/54 Key]

F-007

Socket power [+ 12 V 15/54 Key]

F-008

Flashing light power [+ 12 V F-058 - 200 A]

F-009

Electronic lift control power ( EDC) [+ 12 V 15/54 Key] Service control valve power: PTO front, PTO rear, differential lock, engagement 4WD [+ 12 V 15/54 Key] Pressure switch and speed sensor power [+ 12 V 15/54 Key] 3rd remote valve valve splitter power [+ 12 V 15/54 Key] Right fan third speed power [+ 12 V F-058 - 200 A] Brake pedal switch power [+ 12 V 15/54 Key] Full beam power [+ 12 V F-058 - 200 A]

F-010

F-011 F-012 F-013 F-014 F-015 F-016

F-017 F-018 F-019

Power supply to work light switch, roof relay and A/C compressor relay [+ 12 V K-001] Air Condition control unit power [+ 12 V 15/54 Key] Left fan fourth speed power [+ 12 V F-058 - 200 A] Power supply A-005 to hand brake switch and diagnostic sockets [+ 12 V F-061 - 10 A]

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WIRING DIAGRAM Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100)

Electrical systems - Harnesses and connectors

COMPONENT F-020

F-022 F-023 F-024 F-025 F-026 F-027 F-028 F-029 F-030 F-031 F-032 F-033 F-034 F-035 F-036 F-037 F-038 F-039 F-040 F-041 F-042 F-044 F-045 F-046 F-047 F-048 F-049

CONNECTIONS

DESCRIPTION WIRING DIAGRAM Wire harnesses - Electrical Power supply A-005 to brake oil level switch, disconnected brake pedals, engine schematic frame 02 (55.100) RPM switches, accelerator pedal [+ 12 V 15/54 Key] Light switching power [+ 12 V 15/54 Key] Wire harnesses - Electrical schematic frame 02 (55.100) 7-pole socket power ISO [+ 12 V K-002] Wire harnesses - Electrical schematic frame 02 (55.100) Position lights power [+ 12 V K-002] Wire harnesses - Electrical schematic frame 02 (55.100) Position lights and backlighting power [+ Wire harnesses - Electrical 12 V K-002] schematic frame 02 (55.100) Clutch pedal switch power [+ 12 V 58 Key] Wire harnesses - Electrical schematic frame 02 (55.100) Engine control unit power [+ 12 V 15/54 Wire harnesses - Electrical schematic frame 02 (55.100) Key] Brake light power [+ 12 V K-001] Wire harnesses - Electrical schematic frame 02 (55.100) Electric seat and reverse gear alarm relay Wire harnesses - Electrical power [+ 12 V 15/54 Key] schematic frame 02 (55.100) Wire harnesses - Electrical Right fan fourth speed power [+ 12 V schematic frame 05 (55.100) F-058 - 200 A] Service socket power [+ 12 V F-058 - 200 Wire harnesses - Electrical schematic frame 02 (55.100) A] Starter switch power [+ 12 V F-058 - 200 Wire harnesses - Electrical schematic frame 02 (55.100) A] Cigar lighter socket power [+ 12 V F-058 - Wire harnesses - Electrical schematic frame 02 (55.100) 200 A] Wire harnesses - Electrical ISOBUS 1 power [+ 12 V G-001 ] schematic frame 13 (55.100) Wire harnesses - Electrical Front wiper power [+ 12 V 15/54 Key] schematic frame 02 (55.100) Light switch power [+ 12 V F-058 - 200 A] Wire harnesses - Electrical schematic frame 02 (55.100) Socket power 8 A [+ 12 V F-058 - 200 A] Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical ISOBUS 2 power [+ 12 V G-001 ] schematic frame 13 (55.100) Front loader controls power [+ 12 V 15/54 Wire harnesses - Electrical schematic frame 23 (55.100) Key] Wire harnesses - Electrical Electronic remote valve power ( EHR ) schematic frame 02 (55.100) Wire harnesses - Electrical Trailer brake power [+ 12 V 15/54 Key] schematic frame 24 (55.100) Power supply ISOBUS +15 [+ 12 V 15/54 Wire harnesses - Electrical schematic frame 02 (55.100) Key] Wire harnesses - Electrical Power supply ISOBUS +30 [+ 12 V F-058 schematic frame 02 (55.100) - 200 A] Rear wiper power [+ 12 V K-026] Wire harnesses - Electrical schematic frame 21 (55.100) Air conditioning fan power [+ 12 V K-026] Wire harnesses - Electrical schematic frame 21 (55.100) Radio power [+ 12 V K-026] Wire harnesses - Electrical schematic frame 21 (55.100) Beacon power [+ 12 V F-058 - 200 A] Wire harnesses - Electrical schematic frame 21 (55.100) Rear work lights power [+ 12 V F-058 Wire harnesses - Electrical 200 A] schematic frame 21 (55.100) 47538922 29/05/2013

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Electrical systems - Harnesses and connectors

COMPONENT F-050

CONNECTIONS

F-051 F-053 F-054 F-055 F-056 F-057 F-058 F-059 F-060 F-060 F-061 G-001

X-500, X-600

G-002

X-012, X-013

GND-000

GND-001

X-280

GND-003

X-400

DESCRIPTION Front work lights power [+ 12 V F-058 200 A] +30 radio power [+ 12 V F-058 - 200 A]

WIRING DIAGRAM Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical Engine fuse 1 [+ 12 V K-200 ] schematic frame 01 (55.100) Wire harnesses - Electrical Engine fuse 2 [+ 12 V K-200 ] schematic frame 01 (55.100) Wire harnesses - Electrical Engine fuse 3 [+ 12 V K-200 ] schematic frame 01 (55.100) Wire harnesses - Electrical Control unit memories ( KAM)(+ 12 V schematic frame 01 (55.100) G-001 ) Glow plug control unit fuse [+ 12 V G-001 ] Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical Cab power fuse [+ 12 V G-001 ] schematic frame 01 (55.100) Wire harnesses - Electrical Engine main fuse [+ 12 V G-001 ] schematic frame 01 (55.100) Air conditioning fan power [+ 12 V K-026] Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical Spare schematic frame 01 (55.100) Control unit memories 2 ( KAM 2)(+ 12 V Wire harnesses - Electrical schematic frame 01 (55.100) G-001) Battery Wire harnesses - Electrical schematic frame 01 (55.100) Alternator Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical General ground schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical Control unit ground CCU schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 12 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical Cab relay and fuse panel ground schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100)

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Electrical systems - Harnesses and connectors

COMPONENT GND-004

CONNECTIONS DESCRIPTION X-403 Roof ground 2

GND-006

X-410

Steering column ground

GND-007

X-420

Engine ground

H-001

X-015, X-016

Horn

H-002

X-039

Radio

H-003

X-082, X-083

Right loudspeaker

H-004

X-084, X-085

Left loudspeaker

H-006

X-389

Reversing alarm beeper

J-001

X-070, X-390

Right rotating beacon

J-002

X-072, X-391

Left rotating beacon

J-003

X-026

Socket 8 A

J-004

X-029

Electric seat connector

J-005

X-027, X-080

Cigar/cigarette lighter socket

J-007

X-078, X-079

Service socket 25 A ISO

J-008

X-099

7-pin ISO socket

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WIRING DIAGRAM Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100)

Electrical systems - Harnesses and connectors

COMPONENT J-009

CONNECTIONS DESCRIPTION X-376 Main diagnostic socket

J-012

X-402, X-501

J-013

X-336

J-014

X-378

J-015

X-395

J-016 K-001 K-002 K-003 K-004 K-005 K-006 K-007 K-008 K-009 K-010 K-011 K-012 K-013 K-014 K-015 K-016 K-017 K-018 K-025 K-026 K-027 K-028 K-029

WIRING DIAGRAM Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical Socket ISO 40 A or NAR 30 A schematic frame 09 (55.100) Electro-hydraulic remote valve diagnostic Wire harnesses - Electrical socket schematic frame 11 (55.100) Wire harnesses - Electrical Socket ISO 11786 schematic frame 17 (55.100) Front loader 7-pin socket Wire harnesses - Electrical schematic frame 23 (55.100) NAR 7-pin socket Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical Service switch relay schematic frame 20 (55.100) Position lights circuit relay Wire harnesses - Electrical schematic frame 20 (55.100) Fuel heater relay Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical Left fan third speed relay schematic frame 05 (55.100) Wire harnesses - Electrical Right fan third speed relay schematic frame 05 (55.100) Wire harnesses - Electrical Left fan fourth speed relay schematic frame 05 (55.100) Wire harnesses - Electrical Right fan fourth speed relay schematic frame 05 (55.100) 3rd remote valve splitter relay Wire harnesses - Electrical schematic frame 10 (55.100) Backup alarm relay Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical Kisa far rolesi/Low beam relay schematic frame 20 (55.100) Wire harnesses - Electrical Uzun far rolesi/High beam relay schematic frame 20 (55.100) Low beam headlights switch relay. Wire harnesses - Electrical schematic frame 20 (55.100) Full beam headlights switch relay. Wire harnesses - Electrical schematic frame 20 (55.100) Front loader relay 1 Wire harnesses - Electrical schematic frame 23 (55.100) Front loader relay 2 Wire harnesses - Electrical schematic frame 23 (55.100) Front loader relay 3 Wire harnesses - Electrical schematic frame 23 (55.100) Italy trailer brake relay Wire harnesses - Electrical schematic frame 24 (55.100) Trailer brake relay Wire harnesses - Electrical schematic frame 24 (55.100) Air conditioning compressor relay Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical Roof power relay schematic frame 21 (55.100) Front working lamp relay Wire harnesses - Electrical schematic frame 21 (55.100) Relay rear work lights Wire harnesses - Electrical schematic frame 21 (55.100) Electro-hydraulic remote valve control Wire harnesses - Electrical relay schematic frame 11 (55.100) 47538922 29/05/2013

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Electrical systems - Harnesses and connectors

COMPONENT K-062

CONNECTIONS

K-063 K-100 K-101 K-102 K-103

X-206

K-200 M-001 M-002

X-010, X-011, X-304 X-056LH

M-003

X-056RH

M-004

X-043

M-005

X-038

M-006

X-074

M-007

X-075A

M-008

X-076, X-077

M-009

X-964

M-010

X-966

R-001

X-041

R-002

X-362

R-003

X-955

R-004

X-956

R-005

X-957

R-006

X-958

R-007

C93LH

R-008

C93RH

R-009

X-398

R-010 S-001

X-207 X-197

S-002

X-509, X-510

DESCRIPTION ISOBUS ECU power relay

WIRING DIAGRAM Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical ISOBUS instrument power relay schematic frame 13 (55.100) Wire harnesses - Electrical Start relay schematic frame 01 (55.100) Wire harnesses - Electrical Battery isolator relay (BDS RESET) schematic frame 01 (55.100) Wire harnesses - Electrical Timer relay (BDS SET) schematic frame 01 (55.100) Wire harnesses - Electrical CAN line relay schematic frame 12 (55.100) Engine supply relay Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical Starter motor schematic frame 01 (55.100) Wire harnesses - Electrical Left fan motor schematic frame 05 (55.100) Wire harnesses - Electrical Right fan motor schematic frame 05 (55.100) Air-conditioning actuator Wire harnesses - Electrical schematic frame 05 (55.100) Rear wiper motor Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical Wiper motor for fixed windscreen schematic frame 08 (55.100) Wire harnesses - Electrical Wiper motor for openable windscreen schematic frame 08 (55.100) Screen wash reservoir with front and rear Wire harnesses - Electrical schematic frame 08 (55.100) pump Wire harnesses - Electrical starter EGR schematic frame 19 (55.100) Valve TVA Wire harnesses - Electrical schematic frame 19 (55.100) Air conditioning temperature potentiometer Wire harnesses - Electrical schematic frame 05 (55.100) Fuel heater resistor Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical Cylinder 1 glow plug schematic frame 19 (55.100) Wire harnesses - Electrical Cylinder 2 glow plug schematic frame 19 (55.100) Wire harnesses - Electrical Cylinder 3 glow plug schematic frame 19 (55.100) Wire harnesses - Electrical Cylinder 4 glow plug schematic frame 19 (55.100) Wire harnesses - Electrical Left fan speed control schematic frame 05 (55.100) Wire harnesses - Electrical Right fan speed control schematic frame 05 (55.100) Electro-hydraulic remote valve CAN line Wire harnesses - Electrical schematic frame 11 (55.100) termination ISOBUS line termination Battery isolator switch Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical Starter switch schematic frame 02 (55.100)

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Electrical systems - Harnesses and connectors

COMPONENT S-003

CONNECTIONS DESCRIPTION X-329 Lift control switch on left mudguard

S-004

X-330

Lift control switch on right mudguard

S-005

X-347

PTO switch on the left fender

S-006

X-349

PTO switch on the right fender

S-007

X-350

Rear PTO Switch

S-008

X-348

Front PTO Switch

S-009

X-352

Synchronised warning light switch PTO

S-010

X-374

Switch 4WD

S-011

X-375

Diff lock switch

S-012

X-030

Fans speed switch

S-013

X-031

HVAC switch

S-014

X-042

Air conditioning pressure switch

S-015

X-065

Work Light Switch

S-016

X-061

Lights switch

S-017

X-064

Cab door switch

S-018

X-032

Rotating beacon switch

S-021

X-093

Left hand brake pedal switch

S-022

X-094

Right foot brake switch

S-023

X-086

3rd spool valve splitter switch

S-032

X-199

LO range switch

S-033

X-308

HI range switch

S-034

X-318

" Shuttle" lever

S-035

X-319

Clutch pedal switch

S-036

X-313

Sensitivity switch

S-037

X-321

Accelerator pedal switch/sensor

S-039

X-250

" Home/Enter" switch

S-040

X-260

" Up/Down" switch

S-041

X-355

Operator present switch

S-042

X-360

Brake fluid level switch

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WIRING DIAGRAM Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100)

Electrical systems - Harnesses and connectors

COMPONENT S-044

CONNECTIONS DESCRIPTION X-357 Clogged engine air filter switch.

WIRING DIAGRAM Wire harnesses - Electrical schematic frame 17 (55.100) Trailer brake pressure switch Wire harnesses - Electrical schematic frame 17 (55.100) Engine oil pressure switch Wire harnesses - Electrical schematic frame 19 (55.100) Hazard light switch Wire harnesses - Electrical schematic frame 22 (55.100) Light control lever Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical Super-gearbox switch schematic frame 04 (55.100) Handbrake switch Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical Trailer brake safety switch schematic frame 24 (55.100) Wire harnesses - Electrical Automatic switch PTO schematic frame 04 (55.100) Wire harnesses - Electrical Brake switch PTO schematic frame 04 (55.100) Electronic remote valve lock switch Wire harnesses - Electrical schematic frame 04 (55.100) Electronic remote valve flow control switch Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical Floating function enabling switch schematic frame 04 (55.100) Wire harnesses - Electrical Differential lock warning light switch schematic frame 04 (55.100) Front wiper switch Wire harnesses - Electrical schematic frame 08 (55.100) Rear windscreen wiper switch Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical Creeper status switch (engaged) [ NC ] schematic frame 14 (55.100) Creeper status switch (disengaged) [ NC ] Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical Switch Park Lock schematic frame 14 (55.100) UP switch on panel Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical DOWN switch on panel schematic frame 15 (55.100) Wire harnesses - Electrical 1-4/5-8 range change switch on panel schematic frame 15 (55.100) Wire harnesses - Electrical Constant engine speed setting switch schematic frame 16 (55.100) Wire harnesses - Electrical Constant engine speed switch ON-OFF schematic frame 16 (55.100) Brake pedals not connected switch Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical Roof lights switch schematic frame 22 (55.100) Wire harnesses - Electrical Front loader control 2 ( Joystik ) schematic frame 23 (55.100) Wire harnesses - Electrical Front loader control 1 ( Joystik ) schematic frame 23 (55.100) Front loader implement locking switch Wire harnesses - Electrical schematic frame 23 (55.100)

S-045

X-359, X-399

S-046

X-959

S-047

X-092

S-048

X-091

S-049

X-192

S-055

X-358

S-056

X-502, X-503

S-057

X-190

S-058

X-351

S-059

X-337

S-060

X-338

S-061

X-339

S-062

X-368

S-063

X-091

S-064

X-036

S-065

X-504

S-066

X-522

S-067

X-315

S-068

X-553

S-069

X-554

S-070

X-555

S-071

X-369

S-072

X-303

S-073

X-356

S-074

X-034

S-075

X-323

S-076

X-317

S-077

X-393

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Electrical systems - Harnesses and connectors

COMPONENT S-078

CONNECTIONS DESCRIPTION X-394 Front loader " antidamping" switch

V-001

X-551

Battery isolator diode

V-002

X-295

Front loader jumper wire diode

W-001

X-009

Jumper wire ( Shunt )

X-001

Main cable - engine junction

X-002

PDU junction

X-004

X-201

X-005

X-207

ISOBUS line connector for implement control instrument Line termination resistor CAN

X-007

X-208, X-209

External implement connector

X-025

Engine - cab splitter

X-035B

Roof work lights jumper connector

X-035C

X-046

Road lights and roof work lights jumper connector Left A/C fan junction

X-047

Right A/C fan junction

X-050

Cab - roof junction

X-063

Roof lights connector

X-071

Right rotating beacon splitter

X-073

Left rotating beacon splitter

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WIRING DIAGRAM Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 12 (55.100) Wire harnesses - Electrical schematic frame 12 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

COMPONENT X-075

CONNECTIONS DESCRIPTION X-075 Wiper for openable windscreen splitter

WIRING DIAGRAM Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical Cab - 3rd remote valve junction schematic frame 10 (55.100) Italy license plate light junction Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical Trailer socket splitter ISO schematic frame 09 (55.100) Main cable - armrest junction Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical Cab - roof power junction schematic frame 21 (55.100) Wire harnesses - Electrical Main cable - ISOBUS junction schematic frame 13 (55.100) Main cable - transmission junction A Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Main cable - transmission junction B Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Cab - transmission power supply junction Wire harnesses - Electrical schematic frame 02 (55.100) Trailer brake air pressure sensor junction Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical Cab - front loader junction 1 schematic frame 23 (55.100) Main cable - Italy trailer brake junction Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical Cab - roof junction 2 schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Reversing alarm junction Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100)

X-087

X-095

X-098

X-100

X-160

X-180

X-188

X-300

X-370

X-372

X-380

X-381

X-385

X-389

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Electrical systems - Harnesses and connectors

COMPONENT X-392

CONNECTIONS DESCRIPTION X-392 Cab - front loader junction 2

X-433

Power ground ISOBUS

X-551 X-570

X-570

Battery isolator diode connector Starter motor ground junction

X-660

Main cable - external ISOBUS junction

X-940

Engine control unit - injectors junction

X-941

Engine control unit - FPT junction

X-949

Engine 1 - Engine 2 junction

Y-001

X-334

Raise solenoid valve EDC

Y-002

X-335

Lower solenoid valve EDC

Y-003

X-344

Rear PTO Solenoid

Y-004

X-346

Front solenoid junction PTO

Y-005

X-343

Differential lock solenoid

Y-006

X-342

Disengagement solenoid 4WD

Y-007

X-088

Air conditioning compressor

Y-008

X-089

3rd remote valve splitter solenoid

Y-009

X-806

" C1" clutch solenoid

Y-010

X-807

" C2" clutch solenoid

Y-011

X-340

" C4" clutch solenoid

Y-012

X-365

" C3" clutch solenoid

Y-013

X-951

Injector cylinder 1

Y-014

X-952

Injector cylinder 2

Y-015

X-953

Injector cylinder 3

Y-016

X-954

Injector cylinder 4

Y-017

X-960

Solenoid valve " wastegate "

Y-018

X-363

Trailer brake solenoid 1

Y-019

X-384

Trailer brake solenoid 2

Y-025

X-189

Rear PTO Brake Solenoid

Y-026

X-183

Creeper solenoid

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WIRING DIAGRAM Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

COMPONENT Y-027

CONNECTIONS DESCRIPTION X-184 "Forward" synchroniser solenoid

Y-028

X-185

"Reverse" synchroniser solenoid

Y-029

X-186

"1-4" synchroniser solenoid

Y-030

X-187

"5-8" synchroniser solenoid

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WIRING DIAGRAM Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schema index DESCRIPTION INDEX DESCRIPTION CONTROL UNITS ISOBUS line connector for implement control display Air-conditioning control unit

COMPONENT

CONNECTIONS

A-022

X-203

A-010

X-045

Central control unit ( CCU)

A-008

X-200, X-210, X-220, X-230, X-240

ISOBUS controller ( TECU)

A-021

X-204

Engine Control Unit ECU

A-006

X-937, X-939

Electro-hydraulic remote valve 1 control ( EHR1) Electro-hydraulic remote valve 2 control ( EHR2) Joystick

A-019

X-396

A-020

X-397

A-018

X-173

Electronic lift mouse

A-011

X-326

Battery isolator control module ( BDS )

A-002

X-008 X-009

Front windscreen wiper timer module

Aâ&#x20AC;&#x201C;017

X-048

Cab relay and fuse panel

A-003

X-110, X-120, X-130, X-140

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WIRING DIAGRAM Wire harnesses - Electrical schematic frame 12 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 12 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100)

Electrical systems - Harnesses and connectors

DESCRIPTION Fuse and relay roof panel

COMPONENT A-004

CONNECTIONS WIRING DIAGRAM X-150 Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) X-534 Wire harnesses - Electrical schematic frame 03 (55.100) X-320 Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical X-450 (CH1), schematic frame 16 (55.100) X-460 (CH2), Wire harnesses - Electrical X-377 (CH3) schematic frame 17 (55.100) X-938 Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical X-533, X-003, schematic frame 01 (55.100) X-004, X-005, X-006, X-007, X-014, X-049, X-434 X-090 Wire harnesses - Electrical schematic frame 22 (55.100)

Electronic lift LED panel

A-012

Gear lever pushbuttons

A-014

Analogue/digital instruments ( ADIC)

A-005

Glowplug control unit

A-009

Power distribution unit ( PDU )

A-001

Flasher Unit

A-007

SENSORS / TRANSDUCERS Lift potentiometer panel

B-002

X-327

Hand throttle potentiometer

B-011

X-324

Clutch pedal potentiometer

B-010

X-322

Radar

B-029

X-333

Pre-catalyser exhaust gas temperature sensor Particulate pre-filter exhaust gas temperature sensor ( DPF ) Phase sensor

B-017

X-946

B-016

X-945

B-020

X-962

Trailer brake air pressure sensor

B-033

X-178

Exhaust gas pressure sensor on the manifold Speed sensor

B-021

X-963

B-009

X-309

Speed sensor PTO

B-005

X-341

Pre/post DPF pressure difference sensor

B-018

X-947

Fuel Level Sensor

B-012

X-354

Arms position sensor

B-001

X-328

1-4 / 5-8 ranges synchroniser position sensor Shuttle synchronizer position sensor

B-030

X-194

B-031

X-195

Water in fuel sensor

B-013

X-950

Transmission oil pressure sensor

B-032

X-196

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Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

Rail pressure sensor

B-023

X-967

Air pressure/temperature sensor

B-019

X-961

Electronic lift right draft sensor

B-004

X-332

Electronic lift left draft sensor

B-003

X-331

Air temperature sensor

B-014

X-942

Check whether the implement specifications are suited to the machine. Exhaust gas temperature sensor on manifold Coolant temperature sensor

B-024

X-968

B-027

X-971

B-025

X-969

Transmission temperature sensor

B-008

X-316

Crankshaft Speed Sensor

B-022

X-965

Fuel volume sensor

B-026

X-970

Lambda sensor

B-015

X-943

Termostato antibrina

B-006

X-044

LIGHTING EQUIPMENT Right license plate light on roof

E-022

X-097

Left license plate light on roof

E-021

X-096

Air conditioning panel illumination

E-001

X-040

Electronic remote valve tail light bulb

E-034

X-171, X-172

Right swivel lamp

E-013

X-018

Left swivel lamp

E-012

X-017

Front right work light on roof

E-007

X-057

Front left work light on roof

E-008

X-058

Right work light on handrail

E-009

X-059

Rear right work light on roof

E-004

X-055

Rear right work light on roof - optional

E-003

X-306

Rear left work light on roof

E-006

X-056

Rear left work light on roof - optional

E-005

X-307

Left work light on handrail

E-010

X-060

Front right direction indicator on handrail

E-019

X-022

Front right direction indicator on cab roof (optional)

E-027

X-022A

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Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100)

Electrical systems - Harnesses and connectors

Front left direction indicator on handrail

E-016

X-021

Front left direction indicator on cab roof (optional) Rear right direction indicator on cab roof

E-026

X-021A

E-028

X-387

Rear left direction indicator on cab roof (optional) Right rear lamp

E-025

X-386

E-020

X-024

Left rear lamp

E-018

X-023

Spot light

E-011

X-054

Interior light

E-002

Front RH headlamp

E-015

X-051, X-052, X-053 X-020

Front LH headlamp

E-014

X-019

FUSES +30 radio power [+ 12 V F-058 - 200 A]

F-051

Full beam power [+ 12 V F-058 - 200 A]

F-015

Power supply A-005 to hand brake switch F-019 and diagnostic sockets [+ 12 V F-061 - 10 A] Power supply A-005 to brake oil level F-020 switch, disconnected brake pedals, engine RPM switches, accelerator pedal [+ 12 V 15/54 Key] Dipped beam power [+ 12 V F-058 - 200 A] F-003 Power CN1A CCU [+ 12 V F-061 - 10 A]

F-002

Air Condition control unit power [+ 12 V 15/54 Key] Engine control unit power [+ 12 V 15/54 Key] Service control valve power: PTO front, PTO rear, differential lock, engagement 4WD [+ 12 V 15/54 Key] Front loader controls power [+ 12 V 15/54 Key] Electronic lift control power ( EDC) [+ 12 V 15/54 Key] Electronic remote valve power ( EHR )

F-017 F-027 F-010

F-039 F-009 F-040

Trailer brake power [+ 12 V 15/54 Key]

F-041

" C&D" clutch power [+ 12 V 15/54 Key]

F-006

Beacon power [+ 12 V F-058 - 200 A]

F-048

Air conditioning fan power [+ 12 V K-026]

F-060

Starter switch power [+ 12 V F-058 - 200 A] F-032

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Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100)

Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100)

Electrical systems - Harnesses and connectors

Light switching power [+ 12 V 15/54 Key]

F-022

Light switch power [+ 12 V F-058 - 200 A] F-036 F-016 Power supply to work light switch, roof relay and A/C compressor relay [+ 12 V K-001] Clutch pedal switch power [+ 12 V 58 Key] F-026 Brake pedal switch power [+ 12 V 15/54 Key] Power supply ISOBUS +15 [+ 12 V 15/54 Key] Power supply ISOBUS +30 [+ 12 V F-058 - 200 A] Flashing light power [+ 12 V F-058 - 200 A] " shuttle" lever and gear change power [+ 12 V 15/54 Key] Front work lights power [+ 12 V F-058 200 A] Rear work lights power [+ 12 V F-058 200 A] Position lights power [+ 12 V K-002]

F-014 F-042 F-044 F-008 F-005 F-050 F-049 F-024

Position lights and backlighting power [+ 12 V K-002] Brake light power [+ 12 V K-001]

F-025 F-028

ISOBUS 1 power [+ 12 V G-001 ]

F-034

ISOBUS 2 power [+ 12 V G-001 ]

F-038

Socket power [+ 12 V 15/54 Key]

F-007

7-pole socket power ISO [+ 12 V K-002]

F-023

Socket power 8 A [+ 12 V F-058 - 200 A]

F-037

Cigar lighter socket power [+ 12 V F-058 200 A] Service socket power [+ 12 V F-058 - 200 A] Right fan fourth speed power [+ 12 V F-058 - 200 A] Left fan fourth speed power [+ 12 V F-058 - 200 A] Radio power [+ 12 V K-026]

F-033 F-031 F-030 F-018 F-047

Fuel heating power [+ 12 V F-058 - 200 A] F-004 3rd remote valve valve splitter power [+ 12 V 15/54 Key] Electric seat and reverse gear alarm relay power [+ 12 V 15/54 Key] Pressure switch and speed sensor power [+ 12 V 15/54 Key] Front wiper power [+ 12 V 15/54 Key]

F-012 F-029 F-011 F-035

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Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100)

Electrical systems - Harnesses and connectors

Rear wiper power [+ 12 V K-026]

F-045

Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100)

Right fan third speed power [+ 12 V F-058 F-013 - 200 A] Left fan speed third power [+ 12 V F-058 - F-001 200 A] Air conditioning fan power [+ 12 V K-026] F-046 Engine fuse 1 [+ 12 V K-200 ]

F-053

Engine fuse 2 [+ 12 V K-200 ]

F-054

Engine fuse 3 [+ 12 V K-200 ]

F-055

Cab power fuse [+ 12 V G-001 ]

F-058

Engine main fuse [+ 12 V G-001 ]

F-059

Glow plug control unit fuse [+ 12 V G-001 ] F-057 Spare

F-060

Control unit memories 2 ( KAM 2)(+ 12 V G-001) Control unit memories ( KAM)(+ 12 V G-001 ) GENERATORS Alternator

F-061

G-002

X-012, X-013

AkĂź/Battery

G-001

X-500, X-600

GROUND CONNECTIONS Control unit ground CCU

GND-001

X-280

General ground

GND-000

Engine ground

GND-007

F-056

X-420

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Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 12 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

Cab relay and fuse panel ground

GND-003

X-400

Massa piantone sterzo

GND-006

X-410

Roof ground 2

GND-004

X-403

ACOUSTIC EQUIPMENT Right loudspeaker

H-003

X-082, X-083

Left loudspeaker

H-004

X-084, X-085

Reversing alarm beeper

H-006

X-389

Horn

H-001

X-015, X-016

Radio

H-002

X-039

SOCKETS Electric seat connector

J-004

X-029

Right rotating beacon

J-001

X-070, X-390

Left-hand beacon

J-002

X-072, X-391

Front loader 7-pin socket

J-015

X-395

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Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100)

Electrical systems - Harnesses and connectors

7-pin ISO socket

J-008

X-099

NAR 7-pin socket

J-016

Socket 8 A

J-003

X-026

Cigar/cigarette lighter socket

J-005

X-027, X-080

Service socket 25 A ISO

J-007

X-078, X-079

Electro-hydraulic remote valve diagnostic socket Main diagnostic socket

J-013

X-336

J-009

X-376

Socket ISO 11786

J-014

X-378

Socket ISO 40 A or NAR 30 A

J-012

X-402, X-501

RELAYS Front loader relay 1

K-014

Front loader relay 2

K-015

Front loader relay 3

K-016

Uzun far rolesi/High beam relay

K-011

Engine supply relay

K-200

Roof power relay

K-026

Backup alarm relay

K-009

Kisa far rolesi/Low beam relay

K-010

Position lights circuit relay

K-002

Service switch relay

K-001

Air conditioning compressor relay

K-025

Electro-hydraulic remote valve control relay Full beam headlights switch relay.

K-029

Low beam headlights switch relay.

K-012

Start relay

K-100

Trailer brake relay

K-018

Italy trailer brake relay

K-017

CAN line relay

K-103

Front working lamp relay

K-027

Relay rear work lights

K-028

K-013

X-206

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Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical schematic frame 12 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100)

Electrical systems - Harnesses and connectors

ISOBUS ECU power relay

K-062

Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100)

ISOBUS instrument power relay

K-063

Right fan fourth speed relay

K-007

Left fan fourth speed relay

K-006

Fuel heater relay

K-003

3rd remote valve splitter relay

K-008

Battery isolator relay (BDS RESET)

K-101

Timer relay (BDS SET)

K-102

Right fan third speed relay

K-005

Left fan third speed relay

K-004

MOTORS / ACTUATORS Air-conditioning actuator

M-004

X-043

Wiper motor for openable windscreen

M-007

X-075A

Wiper motor for fixed windscreen

M-006

X-074

Rear wiper motor

M-005

X-038

Right fan motor

M-003

X-056RH

Left fan motor

M-002

X-056LH

Starte motor

M-001

starter EGR

M-009

X-010, X-011, X-304 X-964

Screen wash reservoir with front and rear M-008 pump Valve TVA M-010

X-076, X-077 X-966

ELECTRICAL RESISTORS Cylinder 1 glow plug

R-003

X-955

Cylinder 2 glow plug

R-004

X-956

Cylinder 3 glow plug

R-005

X-957

Cylinder 4 glow plug

R-006

X-958

Air conditioning temperature potentiometer R-001

X-041

Right fan speed control

R-008

C93RH

Left fan speed control

R-007

C93LH

Fuel heater resistor

R-002

X-362

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Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

Electro-hydraulic remote valve CAN line termination SWITCHES Front loader control 1 ( Joystik )

R-009

X-398

Wire harnesses - Electrical schematic frame 11 (55.100)

S-076

X-317

Front loader control 2 ( Joystik )

S-075

X-323

Light control lever

S-048

X-091

Front loader " antidamping" switch

S-078

X-394

" Home/Enter" switch

S-039

X-250

" Up/Down" switch

S-040

X-260

Switch 4WD

S-010

X-374

HVAC switch

S-013

X-031

Floating function enabling switch

S-061

X-339

Diff lock switch

S-011

X-375

Front loader implement locking switch

S-077

X-393

1-4/5-8 range change switch on panel

S-070

X-555

Starter switch [+12V F-032 - 40A]

S-002

X-509, X-510

Lights switch

S-016

X-061

Electronic remote valve lock switch

S-059

X-337

Hazard light switch

S-047

X-092

Engine oil pressure switch

S-046

X-959

Trailer brake safety switch

S-056

X-502, X-503

DOWN switch on panel

S-069

X-554

Clogged engine air filter switch.

S-044

X-357

Handbrake switch

S-055

X-358

Brake switch PTO

S-058

X-351

HI range switch

S-033

X-308

LO range switch

S-032

X-199

Rotating beacon switch

S-018

X-032

Constant engine speed setting switch

S-071

X-369

Brake fluid level switch

S-042

X-360

Work Light Switch

S-015

X-065

Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100)

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Electrical systems - Harnesses and connectors

Roof lights switch

S-074

X-034

Switch Park Lock

S-067

X-315

Right foot brake switch

S-022

X-094

Left hand brake pedal switch

S-021

X-093

Clutch pedal switch

S-035

X-319

Brake pedals not connected switch

S-073

X-356

Cab door switch

S-017

X-064

Operator present switch

S-041

X-355

Air conditioning pressure switch

S-014

X-042

Trailer brake pressure switch

S-045

X-359, X-399

Front PTO Switch

S-008

X-348

Automatic switch PTO

S-057

X-190

Rear PTO Switch

S-007

X-350

PTO switch on the right fender

S-006

X-349

PTO switch on the left fender

S-005

X-347

Sensitivity switch

S-036

X-313

Constant engine speed switch ON-OFF

S-072

X-303

Electronic remote valve flow control switch S-060

X-338

3rd spool valve splitter switch

S-023

X-086

Lift control switch on right mudguard

S-004

X-330

Lift control switch on left mudguard

S-003

X-329

Differential lock warning light switch

S-062

X-368

Synchronised warning light switch PTO

S-009

X-352

Battery isolator switch

S-001

X-197

Creeper status switch (engaged) [ NC ]

S-065

X-504

Creeper status switch (disengaged) [ NC ] S-066

X-522

Super-gearbox switch

S-049

X-192

Front wiper switch

S-063

X-091

Rear windscreen wiper switch

S-064

X-036

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Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

UP switch on panel

S-068

X-553

Fans speed switch

S-012

X-030

Accelerator pedal switch/sensor

S-037

X-321

" Shuttle" lever

S-034

X-318

DIODES Battery isolator diode

V-001

X-551

Front loader jumper wire diode

V-002

X-295

JUMPERS / SHUNT Jumper wire ( Shunt )

W-001

X-009

X-551 X-203

X-203

X-007

X-208, X-209

USB extension interface connector Roof lights connector

X-736 X-063

Roof work lights jumper connector

X-035B

Road lights and roof work lights jumper connector ISOBUS line connector for implement control instrument Cab - front loader junction 1

X-035C

X-004

X-201

X-380

Cab - front loader junction 2

X-392

Cab - roof junction 2

X-385

Main cable - transmission junction A

X-188

Reversing alarm junction

X-389

CONNECTORS Battery isolator diode connector ISOBUS line connector for implement control display External implement connector

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Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100)

Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 12 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100)

Electrical systems - Harnesses and connectors

Main cable - transmission junction B

X-300

Cab - 3rd remote valve junction

X-087

Cab - roof junction

X-050

Main cable - armrest junction

X-100

Main cable - Italy trailer brake junction

X-381

Main cable - ISOBUS junction

X-180

Main cable - external ISOBUS junction

X-660

Main cable - engine junction

X-001

Engine control unit - FPT junction

X-941

Engine control unit - injectors junction

X-940

Italy license plate light junction

X-095

Right rotating beacon splitter

X-071

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Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical schematic frame 12 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

Left rotating beacon splitter

X-073

Starter motor ground junction

X-570

Engine - cab splitter

X-025

Engine 1 - Engine 2 junction

X-949

PDU junction

X-002

Cab - roof power junction

X-160

Cab - transmission power supply junction

X-370

Trailer socket splitter ISO

X-098

Trailer brake air pressure sensor junction

X-372

Right A/C fan junction

X-047

Left A/C fan junction

X-046

Wiper for openable windscreen splitter

X-075

Power ground ISOBUS

X-433

Line termination resistor CAN

X-005

X-207

SOLENOIDS / SOLENOID VALVES Air conditioning compressor

Y-007

X-088

Solenoid valve " wastegate "

Y-017

X-960

Lower solenoid valve EDC

Y-002

x-335

Raise solenoid valve EDC

Y-001

x-334

Front solenoid junction PTO

Y-004

X-346

Injector cylinder 1

Y-013

X-951

Injector cylinder 2

Y-014

X-952

Injector cylinder 3

Y-015

X-953

Injector cylinder 4

Y-016

X-954

Trailer brake solenoid 1

Y-018

X-363

Trailer brake solenoid 2

Y-019

X-384

Differential lock solenoid

Y-005

X-343

Disengagement solenoid 4WD

Y-006

X-342

Rear PTO Brake Solenoid

Y-025

X-189

" C1" clutch solenoid

Y-009

X-806

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Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 12 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

" C2" clutch solenoid

Y-010

X-807

" C3" clutch solenoid

Y-012

X-365

" C4" clutch solenoid

Y-011

X-340

Rear PTO Solenoid

Y-003

X-344

3rd remote valve splitter solenoid

Y-008

X-089

"1-4" synchroniser solenoid

Y-029

X-186

"5-8" synchroniser solenoid

Y-030

X-187

"Forward" synchroniser solenoid

Y-027

X-184

"Reverse" synchroniser solenoid

Y-028

X-185

Creeper solenoid

Y-026

X-183

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Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 01 BATTERY, ALTERNATOR AND POWER SUPPLY UNIT (with battery isolator) T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE

COMPONENT A-001 A-002 F-053 F-054 F-055 F-056 F-057 F-058 F-059 F-060 F-061 G-001 G-002 GND-000 GND-007 K-100 K-101 K-102 K-200 M-001 S-001 V-001 W-001 X-001 X-002 X-433 X-570

20 A 7,5 A 7,5 A 10 A 60 A 200 A 60 A 10 A

DESCRIPTION Power distribution unit ( PDU) Battery isolator control module ( BDS) Engine fuse 1 [+ 12 V K-200] Engine fuse 2 [+ 12 V K-200] Engine fuse 3 [+ 12 V K-200] Control unit memories ( KAM)(+ 12 V G-001) Glowplug control unit fuse [+ 12 V G-001] Cab power fuse [+ 12 V G-001] Engine main fuse [+ 12 V G-001] Spare Control unit memories 2 ( KAM 2)(+ 12 V G-001) Battery Alternator General ground Engine ground Start relay Battery isolator relay ( BDS RESET) Timer relay ( BDS SET) Engine supply relay Starter motor Battery isolator switch Battery isolator diode Jumper wire (Shunt) Main cable - engine junction PDU junction Power ground ISOBUS Starter motor ground junction

*: the battery isolator module ( A-002) and the fuse F-061 are located alongside the battery.

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

MOIL12TR00803JA

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 01 BATTERY, ALTERNATOR AND POWER SUPPLY UNIT (with and without battery isolator) T5.95 ElectroCommand NA, T5.105 ElectroCommand NA, T5.115 ElectroCommand NA

COMPONENT A-001 A-002 * F-053 F-054 F-055 F-056 F-057 F-058 F-059 F-060 G-001 G-002 GND-000 GND-007 K-100 K-101 * K-102 * K-200 M-001 S-001 * V-001 * W-001 * X-001 X-002 X-433 X-570

20 A 7,5 A 7,5 A 10 A 60 A 200 A 60 A

DESCRIPTION Power distribution unit ( PDU) Battery isolator control module ( BDS) Engine fuse 1 [+ 12 V K-200] Engine fuse 2 [+ 12 V K-200] Engine fuse 3 [+ 12 V K-200] Control unit memory - Keep alive memory ( KAM)[+ 12 V G-001] Glowplug control unit fuse [+ 12 V G-001] Cab power fuse [+ 12 V G-001] Engine main fuse [+ 12 V G-001] Spare Battery Alternator General ground Engine ground Start relay Battery isolator relay ( BDS RESET) Timer relay ( BDS SET) Engine supply relay Starter motor Battery isolator switch Battery isolator diode Jumper ( Shunt) Main cable - engine junction PDU junction Power ground ISOBUS Starter motor ground junction

> : connection for version without battery isolator module ( A-002) >> : connection for version with battery isolator module ( A-002) installed internally in power distribution unit ( A-001) *: component only present in some versions

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Electrical systems - Harnesses and connectors

MOIL12TR00810JA

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 02 FUSES COMPONENT A-003 F-003 F-008 F-014 F-015 F-016

15 A 15 A 5A 15 A 15 A

F-019

F-020

F-022 F-023 F-024 F-025 F-026 F-027 F-028 F-029 F-031 F-032 F-033 F-035 F-036 F-037 F-040 F-042 F-044 S-002 X-370 X-385

10 A 10 A 5A 7,5 A 5A 5A 15 A 10 A 40 A 15 A 10 A 5A 10 A 10 A 10 A 10 A

* : for ISO 30 A or 40 A fuse ** :for NAR 30 A fuse

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DESCRIPTION Cab relay and fuse panel Low beam power [+ 12 V F-058 - 200 A] Flashing light power [+ 12 V F-058 - 200 A] Brake pedal switch power [+ 12 V 15/54 Key] Full beam power [+ 12 V F-058 - 200 A] Power supply to work light switch, roof relay and A/C compressor relay [+ 12 V K-001] Power supply A-005 to hand brake switch and diagnostic sockets [+ 12 V F-061 10 A] Power supply A-005 to brake oil level switch, disconnected brake pedals, engine RPM switches, accelerator pedal [+ 12 V 15/54 Key] Light switching power [+ 12 V 15/54 Key] 7-pole ISO socket power 12 V [+ K-002 ] Side lights power [+ 12 V K-002] Side lights and backlighting power [+ 12 V K-002] Clutch pedal switch power [+ 12 V 58 Key] Engine control unit power [+ 12 V 15/54 Key] Brake light power [+ 12 V K-001] Electric seat and reversing alarm relay power [+ 12 V 15/54 Key] Service socket power [+ 12 V F-058 - 200 A] Starter switch power [+ 12 V F-058 - 200 A] Cigar lighter socket power [+ 12 V F-058 - 200 A] Front wiper power [+ 12 V 15/54 Key] Light switch power [+ 12 V F-058 - 200 A] 8A socket power [+ 12 V F-058 - 200 A] Electro-hydraulic remote valve power ( EHR ) Power supply ISOBUS +15 [+ 12 V 15/54 Key] Power ISOBUS +30 [+ 12 V F-058 - 200 A] Starter switch [+ 12 V F-032 - 40 A] Cab - transmission power supply junction Cab - roof junction 2

Electrical systems - Harnesses and connectors

MOIL12TR00804JA

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 03 ELECTRONIC LIFT (EDC) COMPONENT A-003 A-008 A-011 A-012 B-001 B-002 B-003 B-004 B-029 F-009 S-003 S-004 X-188 X-300 Y-001 Y-002

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DESCRIPTION Cab relay and fuse panel Central control unit ( CCU) Electronic lift mouse Electronic lift LED panel Arms position sensor Lift potentiometer panel Electronic lift left draft sensor Electronic lift right draft sensor Radar Electronic lift control power ( EDC) [+ 12 V 15/54 Chiave] Lift control switch on left mudguard Lift control switch on right mudguard Main cable - transmission junction A Main cable - transmission junction B Raise solenoid valve EDC Lower solenoid valve EDC

Electrical systems - Harnesses and connectors

MOIL12TR00631JA

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 04 POWER TAKE OFF, DIFFERENTIAL LOCK, 4 WHEEL DRIVE Frequency of service intervals A-003 A-008 B-005 E-034 F-010 10 A GND-001 S-005 S-006 S-007 S-008 S-009 S-010 S-011 S-049 S-057 S-058 S-059 S-060 S-061 S-062 X-001 X-100 X-300 Y-003 Y-004 Y-005 Y-006 Y-025

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DESCRIPTION Cab relay and fuse panel Central control unit ( CCU) Speed sensor PTO Electronic remote valve tail light bulb Service control valve power: PTO front, PTO rear, differential lock, engagement 4WD [+ 12 V 15/54 Key] Control unit grounds CCU PTO switch on the left fender PTO switch on the right fender Rear PTO Switch Front PTO Switch Synchronised warning light switch PTO Switch 4WD Diff lock switch Super-gearbox switch Automatic switch PTO Brake switch PTO Electronic remote valve lock switch Electronic remote valve flow control switch Floating function enabling switch Differential lock warning light switch Main splitting cable - engine Main splitting cable - armrest Main splitting cable B - transmission Rear PTO Solenoid Front solenoidal splitting PTO Differential lock solenoid Disengagement solenoid 4WD Rear PTO Brake Solenoid

Electrical systems - Harnesses and connectors

MOIL12TR00632JA

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 05 AIR CONDITIONED COMPONENT A-003 X-001 A-004 A-010 B-006 E-001 F-001 F-013 F-017 F-018 F-030 GND-000 GND-003 GND-004 GND-006 GND-007 K-004 K-005 K-006 K-007 K-025 M-002 M-003 M-004 R-001 R-007 R-008 S-012 S-013 S-014 X-046 X-047 X-050 Y-007

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15 A 15 A 5A 20 A 20 A

DESCRIPTION Cab relay and fuse panel Main cable - engine junction Fuse and relay roof panel Air-conditioning control unit Termostato antibrina Air conditioning panel illumination Left fan speed third power [+ 12 V F-058 - 200 A] Right fan third speed power [+ 12 V F-058 - 200 A] Air Condition control unit power [+ 12 V 15/54 Key] Left fan fourth speed power [+ 12 V F-058 - 200 A] Right fan fourth speed power [+ 12 V F-058 - 200 A] General ground Cab relay and fuse panel ground Roof ground 2 Massa piantone sterzo Engine ground Left fan third speed relay Right fan third speed relay Left fan fourth speed relay Right fan fourth speed relay Air conditioning compressor relay Left fan motor Right fan motor Air-conditioning actuator Air conditioning temperature potentiometer Left fan speed control Right fan speed control Fans speed switch HVAC switch Air conditioning pressure switch Left A/C fan junction Right A/C fan junction Cab - roof junction Air conditioning compressor

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 06 WORKLAMPS T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE

COMPONENT E-002 E-003 E-004 E-005 E-006 E-007 E-008 E-009 E-010 E-011 GND-004 S-015 S-016 S-017 X-035B X-035C X-050 X-063

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DESCRIPTION Interior light Rear right work light on roof - optional Rear right work light on roof Rear left work light on roof - optional Rear left work light on roof Front right work light on roof Front left work light on roof Right work light on handrail Left work light on handrail Spot light Roof ground 2 Work Light Switch Lights switch Cab door switch Roof work lights jumper connector Road lights and roof work lights jumper connector Cab - roof junction Roof lights connector

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 06 WORK LIGHTS T5.95 ElectroCommand NA, T5.105 ElectroCommand NA, T5.115 ElectroCommand NA

COMPONENT E-002 E-004 E-006 E-007 E-008 E-011 GND-004 S-015

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DESCRIPTION Interior light Rear right work light on roof Rear left work light on roof Front right work light on roof Front left work light on roof Spot light Roof ground 2 Work Light Switch

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 07 ROAD LIGHTS T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE

COMPONENT E-012 E-013 E-014 E-015 E-016 E-018 E-019 E-020 E-025 E-026 E-027 E-028 GND-003 GND-004 GND-007 H-001 X-001 X-025 X-050 X-385

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DESCRIPTION Left swivel lamp Right swivel lamp Front LH headlamp Front RH headlamp Front left direction indicator on handrail Left rear lamp Front right direction indicator on handrail Right rear lamp Rear left direction indicator on cab roof (optional) Front left direction indicator on cab roof (optional) Front right direction indicator on cab roof (optional) Rear right direction indicator on cab roof Cab relay and fuse panel ground Roof ground 2 Engine ground Horn Main cable - engine junction Engine - cab splitter Cab - roof junction Cab - roof splitter

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 07 ROAD LIGHTS T5.95 ElectroCommand NA, T5.105 ElectroCommand NA, T5.115 ElectroCommand NA

COMPONENT E-012 E-013 E-014 E-015 E-018 E-020 E-025 E-026 E-027 E-028 GND-003 GND-004 GND-007 H-001 X-001 X-025 X-050 X-385

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DESCRIPTION Left swivel lamp Right swivel lamp Front LH headlamp Front RH headlamp Left rear lamp Right rear lamp Rear left direction indicator on cab roof (optional) Front left direction indicator on cab roof (optional) Front right direction indicator on cab roof (optional) Rear right direction indicator on cab roof Cab relay and fuse panel ground Roof ground 2 Engine ground Horn Main cable - engine junction Engine - cab splitter Cab - roof junction Cab - roof splitter

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 08 WINDSCREEN WIPERS AND ROTATING BEACONS COMPONENT A-017 GND-003 GND-004 GND-006 J-001 J-002 M-005 M-006 M-007 M-008 S-018 S-063 S-064 X-050 X-071 X-073 X-075 X-385 *: present only in version ISO

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DESCRIPTION Front windscreen wiper timer module Cab relay and fuse panel ground Roof ground 2 Steering column ground Rotating Beacon Right Hand Left-hand beacon Rear wiper motor Wiper motor for fixed windscreen Wiper motor for openable windscreen Screen wash reservoir with front and rear pump Rotating beacon switch Front wiper switch Rear windscreen wiper switch Cab - roof junction Right rotating beacon splitter Left rotating beacon splitter Wiper for openable windscreen splitter Cab - roof junction 2

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 09 SERVICE SOCKETS COMPONENT A-003 F-007 GND-003 GND-006 J-003 J-004 J-005 J-007 J-008 J-012 J-016 X-098

20 A

*: socket ISO 40 A **: socket NAR 30 A

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DESCRIPTION Cab relay and fuse panel Socket power [+ 12 V 15/54 Key] Cab relay and fuse panel ground Steering column ground Socket 8 A Electric seat connector Cigar/cigarette lighter socket Service socket 25 A ISO ISO 7-pin socket Socket ISO 40 A or NAR 30 A NAR 7-pin socket Trailer socket splitter ISO

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 10 BRAKE PEDALS, LICENSE PLATE LIGHT AND 3RD REMOTE VALVE COMPONENT A-003 E-021 E-022 F-012 GND-001 GND-004 K-008 S-021 S-022 S-023 X-087 X-095 X-389 Y-008

7,5 A

*: presente solo nella versione ISO

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DESCRIPTION Cab relay and fuse panel Left license plate light on roof Right license plate light on roof 3rd remote valve valve splitter power [+ 12 V 15/54 Key] Control unit grounds CCU Roof ground 2 3rd remote valve splitter relay Left hand brake pedal switch Right foot brake switch 3rd spool valve splitter switch Cab - 3rd remote valve junction Italy license plate light junction Reversing alarm junction 3rd remote valve splitter solenoid

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 11 CAN LINE COMPONENT A-003 A-018 A-019 A-020 GND-003 J-009 J-013 K-029 R-009 X-001 X-100 X-188

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DESCRIPTION Cab relay and fuse panel Joystick Electro-hydraulic remote valve 1 control ( EHR1) Electro-hydraulic remote valve 2 control ( EHR2) Cab relay and fuse panel ground Main diagnostic socket Electro-hydraulic remote valve diagnostic socket Electro-hydraulic remote valve control relay Electro-hydraulic remote valve CAN line termination Main cable - engine junction Main cable - armrest junction Main cable - transmission junction A

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 12 INTERNAL ISOBUS LINE TO CAB COMPONENT A-021 A-022 GND-001 K-103 X-180 X-004 X-005

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DESCRIPTION Control unit ISOBUS ( TECU) ISOBUS line connector for implement control display Control unit ground CCU CAN line relay Main cable - ISOBUS junction ISOBUS line connector for implement control instrument Line end resistance CAN

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 13 EXTERNAL ISOBUS LINE TO CAB F-034 F-038 K-062 K-063 X-007 X-180 X-660

COMPONENT 40 A 20 A

*: only in present in ISO version

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DESCRIPTION ISOBUS 1 power supply [+ 12 V G-001] ISOBUS 2 power supply [+ 12 V G-001] ISOBUS ECU power relay ISOBUS instrument power relay External implement connector Main cable - ISOBUS junction Main cable - external ISOBUS junction

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 14 TRANSMISSION CONTROL 1 COMPONENT A-003 A-008 B-008 B-009 B-030 B-031 B-032 F-011 S-032 S-033 S-065 S-066 S-067 X-188 X-300 Y-009 Y-010 Y-011 Y-012 Y-026 Y-027 Y-028 Y-029 Y-030

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DESCRIPTION Cab relay and fuse panel Central control unit ( CCU) Transmission temperature sensor Speed sensor 1-4 / 5-8 ranges synchroniser position sensor Shuttle synchronizer position sensor Transmission oil pressure sensor Pressure switch and speed sensor power [+ 12 V 15/54 Key] LO range switch HI range switch Creeper status switch (engaged) [ NC ] Creeper status switch (disengaged) [ NC ] Switch Park Lock Main cable - transmission junction A Main cable - transmission jucntion B " C1" clutch solenoid " C2" clutch solenoid " C3" clutch solenoid " C4" clutch solenoid Creeper solenoid "Forward" synchroniser solenoid "Reverse" synchroniser solenoid "1-4" synchroniser solenoid "5-8" synchroniser solenoid

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 15 TRANSMISSION CONTROL 2 COMPONENT A-003 A-008 A-014 B-010 F-002 F-005 F-006 GND-001 GND-003 H-006 K-009 S-034 S-035 S-036 S-068 S-069 S-070 X-001 X-188 X-300 X-389

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5A 7,5 A 7,5 A

DESCRIPTION Cab relay and fuse panel Central control unit ( CCU) Gear lever pushbuttons Clutch pedal potentiometer CN1A CCU power [+ 12 V F-061 - 10 A] " shuttle" lever and gear change power [+ 12 V 15/54 Key] " C&D" clutch power [+ 12 V 15/54 Key] Control unit ground CCU Cab relay and fuse panel ground Reversing alarm beeper Reversing alarm relay " Shuttle" lever Clutch pedal switch Sensitivity switch UP switch on panel DOWN switch on panel 1-4/5-8 range change switch on panel Main cable - engine junction Main cable - transmission junction A Main cable - transmission jucntion B Reversing alarm junction

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 16 INSTRUMENT PANEL CONTROL UNIT 1 COMPONENT A-005 B-011 B-033 GND-001 GND-006 S-037 S-039 S-040 S-071 S-072 X-372

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DESCRIPTION Analogue/digital instruments ( ADIC) Hand throttle potentiometer Trailer brake air pressure sensor Control unit ground CCU Steering column ground Accelerator pedal switch/sensor " Home/Enter" switch " Up/Down" switch Constant engine speed setting switch Constant engine speed switch ON-OFF Trailer brake air pressure sensor junction

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 17 INSTRUMENT PANEL CONTROL UNIT 2 COMPONENT A-005 B-012 GND-006 J-014 S-041 S-042 S-044 S-045 S-073 X-001 X-300 X-381

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DESCRIPTION Analogue/digital instruments ( ADIC) Fuel Level Sensor Steering column ground Socket ISO 11786 Operator present switch Brake fluid level switch Clogged engine air filter switch. Trailer brake pressure switch Brake pedals not connected switch Main cable - engine junction Main cable - transmission junction B Main cable - Italy trailer brake junction

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 18 ENGINE CONTROLS 2 COMPONENT A-003 A-006 B-013 B-014 B-015 B-016 B-017 B-018 F-004 GND-007 K-003 R-002 X-001 X-949

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20 A

DESCRIPTION Cab relay and fuse panel Engine control unit ECU Water in fuel sensor Air temperature sensor Lambda sensor Particulate pre-filter exhaust gas temperature sensor ( DPF ) Pre-catalyser exhaust gas temperature sensor Pre/post DPF pressure difference sensor Fuel heating power [+ 12 V F-058 - 200 A] Engine ground Fuel heater relay Fuel heater resistor Main cable - engine junction Engine 1 - Engine 2 junction

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 19 ENGINE CONTROLS 1 COMPONENT A-006 A-009 B-019 B-020 B-021 B-022 B-023 B-024 B-025 B-026 B-027 GND-000 M-009 M-010 R-003 R-004 R-005 R-006 S-046 X-940 X-941 Y-013 Y-014 Y-015 Y-016 Y-017

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DESCRIPTION Engine Control Unit ECU Glowplug control unit Air pressure/temperature sensor Phase sensor Exhaust gas pressure sensor on the manifold Crankshaft Speed Sensor Rail pressure sensor Check whether the implement specifications are suited to the machine. Coolant temperature sensor Fuel volume sensor Exhaust gas temperature sensor on manifold General ground starter EGR Valve TVA Cylinder 1 glow plug Cylinder 2 glow plug Cylinder 3 glow plug Cylinder 4 glow plug Engine oil pressure switch Engine control unit - injectors junction Engine control unit - FPT junction Injector cylinder 1 Injector cylinder 2 Injector cylinder 3 Injector cylinder 4 Solenoid valve " wastegate "

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 20 RELAYS COMPONENT A-003 K-001 K-002 K-010 K-011 K-012 K-013 X-050 X-385 *: applies only to ISO version

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DESCRIPTION Cab relay and fuse panel Service switch relay Position lights circuit relay Kisa far rolesi/Low beam relay Uzun far rolesi/High beam relay Low beam headlights switch relay. Full beam headlights switch relay. Cab - roof junction Cab - roof junction 2

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 21 ROOF FUSES AND RELAYS COMPONENT A-004 F-045 F-046 F-047 F-048 F-049 F-050 F-051 F-060 GND-004 K-026 K-027 K-028 X-160

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10 A 20 A 7,5 A 15 A 20 A 15 A 7,5 A 5A

DESCRIPTION Fuse and relay roof panel Rear wiper power [+ 12 V K-026] Air conditioning fan power [+ 12 V K-026] Radio power [+ 12 V K-026] Beacon power [+ 12 V F-058 - 200 A] Rear work lights power [+ 12 V F-058 - 200 A] Front work lights power [+ 12 V F-058 - 200 A] +30 radio power [+ 12 V F-058 - 200 A] Air conditioning fan power [+ 12 V K-026] Roof ground 2 Roof power relay Front working lamp relay Relay rear work lights Cab - roof power junction

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 22 FLASHER UNIT, LIGHTS CONTROL SWITCH AND RADIO COMPONENT A-007 GND-003 GND-004 GND-006 H-002 H-003 H-004 S-047 S-048 S-074 X-385

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DESCRIPTION Flasher Unit Cab relay and fuse panel ground Roof ground 2 Massa piantone sterzo Radio Right loudspeaker Left loudspeaker Hazard light switch Light control lever Roof lights switch Cab - roof junction 2

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 23 FRONT-END LOADER F-039 J-015 K-014 K-015 K-016 S-075 S-076 S-077 S-078 V-002 X-380 X-392

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COMPONENT 7,5 A

DESCRIPTION Front loader controls power [+ 12 V 15/54 Key] Front loader 7-pin socket Front loader relay 1 Front loader relay 2 Front loader relay 3 Front loader control 2 ( Joystik ) Front loader control 1 ( Joystik ) Front loader implement locking switch Front loader " antidamping" switch Front loader jumper wire diode Cab - front loader junction 1 Cab - front loader junction 2

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 24 ITALIAN TRAILER BRAKE COMPONENT A-003 F-041 K-017 K-018 S-055 S-056 X-381 Y-018 Y-019

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DESCRIPTION Cab relay and fuse panel Trailer brake power [+ 12 V 15/54 Key] Italy trailer brake relay Trailer brake relay Handbrake switch Trailer brake safety switch Main cable - Italy trailer brake junction Trailer brake solenoid 1 Trailer brake solenoid 2

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Component localisation CONNECTIONS C93LH C93RH X-001 X-002 X-008 X-009 X-009 X-010, X-011, X-304 X-012, X-013 X-015, X-016 X-017 X-018 X-019 X-020 X-021 X-022 X-023 X-024 X-025 X-026 X-027, X-080 X-029 X-030 X-031 X-032 X-034 X-036 X-038 X-039 X-040 X-041 X-043 X-044 X-045 X-046 X-047 X-048 X-050 X-051, X-052, X-053 X-054 X-055 X-056 X-056LH X-056RH X-057 X-058 X-059 X-060 X-061 X-063 X-064 X-065

COMPONENT

DESCRIPTION

WIRING LOOM DRAWING

R-007 R-008 X-001 X-002 A-002 W-001 M-001

Left fan speed control Right fan speed control Main cable - engine junction PDU junction Battery isolator control module ( BDS ) Jumper wire ( Shunt ) Starte motor

08 07 03, 07 04 04 04 04

G-002 H-001 E-012 E-013 E-014 E-015 E-016 E-019 E-018 E-020 X-025 J-003 J-005 J-004 S-012 S-013 S-018 S-074 S-064 M-005 H-002 E-001 R-001 M-004 B-006 A-010 X-046 X-047 Aâ&#x20AC;&#x201C;017 X-050 E-002

Alternator Horn Left swivel lamp Right swivel lamp Front LH headlamp Front RH headlamp Front left direction indicator on handrail Front right direction indicator on handrail Left rear lamp Right rear lamp Engine - cab splitter Socket 8 A Cigar/cigarette lighter socket Electric seat connector Fans speed switch HVAC switch Rotating beacon switch Roof lights switch Roof lights switch Rear wiper motor Radio Air conditioning panel illumination Air conditioning temperature potentiometer Air-conditioning actuator Termostato antibrina Air-conditioning control unit Left A/C fan junction Right A/C fan junction Front windscreen wiper timer module Cab - roof junction Interior light

04 10 10 10 10 10 09 09 08 07 03, 10 07 07 08 09 09 09 09 09 09 09 09 09 07 07 07 08 07 08 08, 09 09

E-011 E-004 E-006 M-002 M-003 E-007 E-008 E-009 E-010 S-016 X-063 S-017 S-015

Spot light Rear right work light on roof Rear left work light on roof Left fan motor Right fan motor Front right work light on roof Front left work light on roof Right work light on handrail Left work light on handrail Lights switch Roof lights connector Cab door switch Work Light Switch

09 09 09 08 07 09 09 09 09 09 09 09 09

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Electrical systems - Harnesses and connectors

CONNECTIONS X-071 X-073 X-074 X-076, X-077 X-078, X-079 X-082, X-083 X-084, X-085 X-086 X-087 X-089 X-090 X-091 X-091 X-092 X-093 X-094 X-095 X-096 X-097 X-098 X-100 X-110, X-120, X-130, X-140 X-150 X-160 X-180 X-183 X-184 X-185 X-186 X-187 X-188 X-189 X-190 X-192 X-194 X-195 X-196 X-197 X-199 X-200, X-210, X-220, X-230, X-240 X-250 X-260 X-280 X-300 X-303 X-306 X-307 X-308 X-309 X-313 X-315

COMPONENT

DESCRIPTION

WIRING LOOM DRAWING

X-071 X-073 M-006 M-008 J-007 H-003 H-004 S-023 X-087 Y-008 A-007 S-048 S-063 S-047 S-021 S-022 X-095 E-021 E-022 X-098 X-100 A-003

Right rotating beacon splitter Left rotating beacon splitter Wiper motor for fixed windscreen Screen wash reservoir with front and rear pump Service socket 25 A ISO Right loudspeaker Left loudspeaker 3rd spool valve splitter switch Cab - 3rd remote valve junction 3rd remote valve splitter solenoid Flasher Unit Light control lever Front wiper switch Hazard light switch Left hand brake pedal switch Right foot brake switch Italy license plate light junction Left license plate light on roof Right license plate light on roof Trailer socket splitter ISO Main cable - armrest junction Cab relay and fuse panel

09 09 07 08 07 09 09 07 05 05 08 08 08 08 07 07 08 09 09 08 07 08

A-004 X-160 X-180 Y-026 Y-027 Y-028 Y-029 Y-030 X-188 Y-025 S-057 S-049 B-030 B-031 B-032 S-001 S-032 A-008

Fuse and relay roof panel Cab - roof power junction Main cable - ISOBUS junction Creeper solenoid "Forward" synchroniser solenoid "Reverse" synchroniser solenoid "1-4" synchroniser solenoid "5-8" synchroniser solenoid Main cable - transmission junction A Rear PTO Brake Solenoid Automatic switch PTO Super-gearbox switch 1-4 / 5-8 ranges synchroniser position sensor Shuttle synchronizer position sensor Transmission oil pressure sensor Battery isolator switch LO range switch Central control unit ( CCU)

09 08, 09 07 05 06 06 05 05 06, 07 05 07 07 05 06 05 08 06 08

S-039 S-040 GND-001 X-300 S-072 E-003 E-005 S-033 B-009 S-036 S-067

" Home/Enter" switch " Up/Down" switch Control unit ground CCU Main cable - transmission junction B Constant engine speed switch ON-OFF Rear right work light on roof - optional Rear left work light on roof - optional HI range switch Speed sensor Sensitivity switch Switch Park Lock

08 08 08 05, 08 07 09 09 06 06 07 06

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Electrical systems - Harnesses and connectors

CONNECTIONS X-316 X-317 X-318 X-319 X-320 X-321 X-322 X-323 X-324 X-326 X-327 X-328 X-329 X-330 X-331 X-332 X-333 x-334 x-335 X-336 X-337 X-340 X-341 X-342 X-343 X-344 X-346 X-347 X-348 X-349 X-350 X-351 X-352 X-354 X-355 X-356 X-357 X-358 X-359, X-399 X-360 X-362 X-363 X-365 X-368 X-369 X-370 X-374 X-375 X-376 X-378 X-380 X-381 X-384 X-385 X-389

COMPONENT B-008 S-076 S-034 S-035 A-014 S-037 B-010 S-075 B-011 A-011 B-002 B-001 S-003 S-004 B-003 B-004 B-029 Y-001 Y-002 J-013 S-059 Y-011 B-005 Y-006 Y-005 Y-003 Y-004 S-005 S-008 S-006 S-007 S-058 S-009 B-012 S-041 S-073 S-044 S-055 S-045 S-042 R-002 Y-018 Y-012 S-062 S-071 X-370 S-010 S-011 J-009 J-014 X-380 X-381 Y-019 X-385 H-006

DESCRIPTION Transmission temperature sensor Front loader control 1 ( Joystik ) " Shuttle" lever Clutch pedal switch Gear lever pushbuttons Accelerator pedal switch/sensor Clutch pedal potentiometer Front loader control 2 ( Joystik ) Hand throttle potentiometer Electronic lift mouse Lift potentiometer panel Arms position sensor Lift control switch on left mudguard Lift control switch on right mudguard Electronic lift left draft sensor Electronic lift right draft sensor Radar Raise solenoid valve EDC Lower solenoid valve EDC Electro-hydraulic remote valve diagnostic socket Electronic remote valve lock switch " C4" clutch solenoid Speed sensor PTO Disengagement solenoid 4WD Differential lock solenoid Rear PTO Solenoid Front solenoid junction PTO PTO switch on the left fender Front PTO Switch PTO switch on the right fender Rear PTO Switch Brake switch PTO Synchronised warning light switch PTO Fuel Level Sensor Operator present switch Brake pedals not connected switch Clogged engine air filter switch. Handbrake switch Trailer brake pressure switch Brake fluid level switch Fuel heater resistor Trailer brake solenoid 1 " C3" clutch solenoid Differential lock warning light switch Constant engine speed setting switch Cab - transmission power supply junction Switch 4WD Diff lock switch Main diagnostic socket Socket ISO 11786 Cab - front loader junction 1 Main cable - Italy trailer brake junction Trailer brake solenoid 2 Cab - roof junction 2 Reversing alarm beeper 47538922 29/05/2013

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WIRING LOOM DRAWING 06 08 08 07 08 08 07 08 07 07 07 05 08 07 05 06 06 05 05 08 08 06 06 05 05 05 04 08 07 07 07 07 06 05 08 07 04 08 05 03 03 05 06 05 07 03, 07 07 08 07 03, 05, 05 08, 07

07 08 09

Electrical systems - Harnesses and connectors

CONNECTIONS X-389 X-392 X-393 X-394 X-395 X-396 X-397 X-398 X-400 X-402, X-501 X-403 X-410 X-420 X-450 (CH1), X-460 (CH2), X-377 (CH3) X-500, X-600 X-502, X-503 X-504 X-509, X-510 X-522 X-533, X-003, X-004, X-005, X-006, X-007, X-014, X-049, X-434 X-534 X-551 X-553 X-554 X-555 X-570 X-806 X-807 X-937, X-939 X-938 X-940 X-941 X-942 X-943 X-945 X-946 X-947 X-949 X-950 X-951 X-952 X-953 X-954 X-955 X-956 X-957 X-958 X-959

COMPONENT

DESCRIPTION

WIRING LOOM DRAWING

X-389 X-392 S-077 S-078 J-015 A-019 A-020 R-009 GND-003 J-012 GND-004 GND-006 GND-007 A-005

Reversing alarm junction Cab - front loader junction 2 Front loader implement locking switch Front loader " antidamping" switch Front loader 7-pin socket Electro-hydraulic remote valve 1 control ( EHR1) Electro-hydraulic remote valve 2 control ( EHR2) Electro-hydraulic remote valve CAN line termination Cab relay and fuse panel ground Socket ISO 40 A or NAR 30 A Roof ground 2 Massa piantone sterzo Engine ground Analogue/digital instruments ( ADIC)

07 07 07 07 04 06 06 06 08 07 09 07 04 08

G-001 S-056 S-065 S-002 S-066 A-001

AkĂź/Battery Trailer brake safety switch Creeper status switch (engaged) [ NC ] Starter switch Creeper status switch (disengaged) [ NC ] Power distribution unit ( PDU )

04 05 05 08 05 04

A-012 V-001 S-068 S-069 S-070 X-570 Y-009 Y-010 A-006 A-009 X-940 X-941 B-014 B-015 B-016

Electronic lift LED panel Battery isolator diode UP switch on panel DOWN switch on panel 1-4/5-8 range change switch on panel Starter motor ground junction " C1" clutch solenoid " C2" clutch solenoid Engine Control Unit ECU Glowplug control unit Engine control unit - injectors junction Engine control unit - FPT junction Air temperature sensor Lambda sensor Particulate pre-filter exhaust gas temperature sensor ( DPF ) Pre-catalyser exhaust gas temperature sensor Pre/post DPF pressure difference sensor Engine 1 - Engine 2 junction Water in fuel sensor Injector cylinder 1 Injector cylinder 2 Injector cylinder 3 Injector cylinder 4 Cylinder 1 glow plug Cylinder 2 glow plug Cylinder 3 glow plug Cylinder 4 glow plug Engine oil pressure switch

07 08 07 07 07 04 06 06 03 03 01, 02, 03 01, 02, 03 04 03 03

B-017 B-018 X-949 B-013 Y-013 Y-014 Y-015 Y-016 R-003 R-004 R-005 R-006 S-046

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03 03 03 03 01 01, 02 01, 02 01, 02 01 01 02 02 01

Electrical systems - Harnesses and connectors

CONNECTIONS X-960 X-961 X-962 X-963 X-964 X-965 X-966 X-967 X-968

COMPONENT Y-017 B-019 B-020 B-021 M-009 B-022 M-010 B-023 B-024

X-969 X-970 X-971

B-025 B-026 B-027

DESCRIPTION Solenoid valve " wastegate " Air pressure/temperature sensor Phase sensor Exhaust gas pressure sensor on the manifold starter EGR Crankshaft Speed Sensor Valve TVA Rail pressure sensor Check whether the implement specifications are suited to the machine. Coolant temperature sensor Fuel volume sensor Exhaust gas temperature sensor on manifold

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WIRING LOOM DRAWING 01, 02 01 01, 02 01, 02 01, 02 01 01, 02 01, 02 01, 02 01, 02 01, 02 01, 02

Electrical systems - Harnesses and connectors

Wire harnesses - Component localisation

MOIL12TR00658HA

Dwg. 01 â&#x20AC;&#x201D; engine cable LH side

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Electrical systems - Harnesses and connectors

MOIL12TR00659HA

Dwg. 02 â&#x20AC;&#x201D; engine cable RH side

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Electrical systems - Harnesses and connectors

MOIL12TR00660HA

Dwg.03 â&#x20AC;&#x201D; engine cable 2 LH side

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Electrical systems - Harnesses and connectors

MOIL12TR00661HA

Dwg.04 â&#x20AC;&#x201D; engine cable 2 RH side

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Electrical systems - Harnesses and connectors

MOIL12TR00662HA

Dwg.05 â&#x20AC;&#x201D; transmission cable LH side

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Electrical systems - Harnesses and connectors

MOIL12TR00663HA

Dwg.06 â&#x20AC;&#x201D; transmission cable RH side

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Electrical systems - Harnesses and connectors

MOIL12TR00664HA

Dwg.07 â&#x20AC;&#x201D; cab cable LH side

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Electrical systems - Harnesses and connectors

MOIL12TR00665HA

Dwg.08 â&#x20AC;&#x201D; cab cable RH side

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Electrical systems - Harnesses and connectors

MOIL12TR00666HA

Dwg.09 â&#x20AC;&#x201D; roof cable

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Electrical systems - Harnesses and connectors

MOIL12TR00667HA

Dwg.10 â&#x20AC;&#x201D; hood cable

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schema ADIC CONTROL UNIT COMPONENT DESCRIPTION A-002 Battery isolator control module ( BDS ) A-005

Analogue/digital instruments ( ADIC)

A-007

Flasher Unit

B-011

Hand throttle potentiometer

B-012

Fuel Level Sensor

B-033

Trailer brake air pressure sensor

F-019

F-024

Power supply A-005 to hand brake switch and diagnostic sockets [+ 12 V F-061 - 10 A] Power supply A-005 to brake oil level switch, disconnected brake pedals, engine RPM switches, accelerator pedal [+ 12 V 15/54 Key] Position lights power [+ 12 V K-002]

F-026

Clutch pedal switch power [+ 12 V 58 Key]

G-001

AkĂź/Battery

G-002

Alternator

J-009

Main diagnostic socket

S-001

Battery isolator switch

S-002

Starter switch

S-015

Work Light Switch

S-037

Accelerator pedal switch/sensor

S-039

" Home/Enter" switch

S-040

" Up/Down" switch

S-041

Operator present switch

S-042

Brake fluid level switch

S-044

Clogged engine air filter switch.

S-045

Trailer brake pressure switch

S-048

Light control lever

S-055

Handbrake switch

S-071

Constant engine speed setting switch

F-020

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WIRING DIAGRAM Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100)

Electrical systems - Harnesses and connectors

COMPONENT DESCRIPTION S-072 Constant engine speed switch ON-OFF S-073

Brake pedals not connected switch

S-074

Roof lights switch

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WIRING DIAGRAM Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100)

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

MOIL12TR00811JA

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schema CCU CONTROL UNIT COMPONENT DESCRIPTION A-008 Central control unit ( CCU)

A-011 A-012 A-014 A-018 B-001 B-002 B-003 B-004 B-005 B-008 B-009 B-010 B-029 B-030 B-031 B-032 E-018 E-020 E-034 F-002 F-005 F-006 F-009 F-010

WIRING DIAGRAM Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic Electronic lift mouse frame 03 (55.100) Wire harnesses - Electrical schematic Electronic lift LED panel frame 03 (55.100) Wire harnesses - Electrical schematic Gear lever pushbuttons frame 15 (55.100) Joystick Wire harnesses - Electrical schematic frame 11 (55.100) Arms position sensor Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic Lift potentiometer panel frame 03 (55.100) Wire harnesses - Electrical schematic Electronic lift left draft sensor frame 03 (55.100) Wire harnesses - Electrical schematic Electronic lift right draft sensor frame 03 (55.100) Wire harnesses - Electrical schematic Speed sensor PTO frame 04 (55.100) Transmission temperature sensor Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic Speed sensor frame 14 (55.100) Wire harnesses - Electrical schematic Clutch pedal potentiometer frame 15 (55.100) Radar Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic 1-4 / 5-8 ranges synchroniser position sensor frame 14 (55.100) Wire harnesses - Electrical schematic Shuttle synchronizer position sensor frame 14 (55.100) Transmission oil pressure sensor Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic Left rear lamp frame 07 (55.100) Right rear lamp Wire harnesses - Electrical schematic frame 07 (55.100) Electronic remote valve tail light bulb Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic Power CN1A CCU [+ 12 V F-061 - 10 A] frame 15 (55.100) " shuttle" lever and gear change power [+ 12 V 15/54 Wire harnesses - Electrical schematic frame 15 (55.100) Key] Wire harnesses - Electrical schematic " C&D" clutch power [+ 12 V 15/54 Key] frame 15 (55.100) Electronic lift control power ( EDC) [+ 12 V 15/54 Key] Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic Service control valve power: PTO front, PTO rear, differential lock, engagement 4WD [+ 12 V 15/54 Key] frame 04 (55.100) 47538922 29/05/2013

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Electrical systems - Harnesses and connectors

COMPONENT DESCRIPTION WIRING DIAGRAM F-011 Pressure switch and speed sensor power [+ 12 V 15/54 Wire harnesses - Electrical schematic frame 14 (55.100) Key] F-014 Wire harnesses - Electrical schematic Brake pedal switch power [+ 12 V 15/54 Key] frame 02 (55.100) F-019 Power supply A-005 to hand brake switch and Wire harnesses - Electrical schematic diagnostic sockets [+ 12 V F-061 - 10 A] frame 02 (55.100) F-024 Position lights power [+ 12 V K-002] Wire harnesses - Electrical schematic frame 02 (55.100) F-026 Wire harnesses - Electrical schematic Clutch pedal switch power [+ 12 V 58 Key] frame 02 (55.100) F-040 Wire harnesses - Electrical schematic Electronic remote valve power ( EHR ) frame 02 (55.100) J-009 Main diagnostic socket Wire harnesses - Electrical schematic frame 11 (55.100) K-009 Backup alarm relay Wire harnesses - Electrical schematic frame 15 (55.100) K-100 Wire harnesses - Electrical schematic Start relay frame 01 (55.100) M-001 Wire harnesses - Electrical schematic Starte motor frame 01 (55.100) Wire harnesses - Electrical schematic S-003 Lift control switch on left mudguard frame 03 (55.100) Wire harnesses - Electrical schematic S-004 Lift control switch on right mudguard frame 03 (55.100) Wire harnesses - Electrical schematic S-005 PTO switch on the left fender frame 04 (55.100) Wire harnesses - Electrical schematic S-006 PTO switch on the right fender frame 04 (55.100) Wire harnesses - Electrical schematic S-007 Rear PTO Switch frame 04 (55.100) Wire harnesses - Electrical schematic S-008 Front PTO Switch frame 04 (55.100) Wire harnesses - Electrical schematic S-009 Synchronised warning light switch PTO frame 04 (55.100) Wire harnesses - Electrical schematic S-010 Switch 4WD frame 04 (55.100) Wire harnesses - Electrical schematic S-011 Diff lock switch frame 04 (55.100) Wire harnesses - Electrical schematic S-021 Left hand brake pedal switch frame 10 (55.100) Wire harnesses - Electrical schematic S-022 Right foot brake switch frame 10 (55.100) Wire harnesses - Electrical schematic S-032 LO range switch frame 14 (55.100) HI range switch Wire harnesses - Electrical schematic S-033 frame 14 (55.100) Wire harnesses - Electrical schematic S-034 " Shuttle" lever frame 15 (55.100) Wire harnesses - Electrical schematic S-035 Clutch pedal switch frame 15 (55.100) Wire harnesses - Electrical schematic S-036 Sensitivity switch frame 15 (55.100) Wire harnesses - Electrical schematic S-049 Super-gearbox switch frame 04 (55.100) Wire harnesses - Electrical schematic S-057 Automatic switch PTO frame 04 (55.100) Wire harnesses - Electrical schematic S-058 Brake switch PTO frame 04 (55.100) 47538922 29/05/2013

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Electrical systems - Harnesses and connectors

COMPONENT DESCRIPTION Electronic remote valve lock switch S-059 S-060

Electronic remote valve flow control switch

S-061

Floating function enabling switch

S-062

Differential lock warning light switch

S-065

Creeper status switch (engaged) [ NC ]

S-066

Creeper status switch (disengaged) [ NC ]

S-067

Switch Park Lock

S-068

UP switch on panel

S-069

DOWN switch on panel

S-070

1-4/5-8 range change switch on panel

S-075

Front loader control 2 ( Joystik )

S-076

Front loader control 1 ( Joystik )

Y-001

Raise solenoid valve EDC

Y-002

Lower solenoid valve EDC

Y-003

Rear PTO Solenoid

Y-004

Front solenoid junction PTO

Y-005

Differential lock solenoid

Y-006

Disengagement solenoid 4WD

Y-009

" C1" clutch solenoid

Y-010

" C2" clutch solenoid

Y-011

" C4" clutch solenoid

Y-012

" C3" clutch solenoid

Y-025

Rear PTO Brake Solenoid

Y-026

Creeper solenoid

Y-027

"Forward" synchroniser solenoid

Y-028

"Reverse" synchroniser solenoid

Y-029

"1-4" synchroniser solenoid

Y-030

"5-8" synchroniser solenoid

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WIRING DIAGRAM Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

MOIL12TR00812JA

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Overview BUS protocol connections and components

MOIL13TR00114AA

A-005

X-450 (CH1), X-460 (CH2), X-377 (CH3)

A-006

X-937, X-939

A-008

X-200, X-210, X-220, X-230, X-240

A-018

X-173

A-019

X-396

A-020

X-397

A-021

X-204

J-009

X-376

J-013

X-336

Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical Engine Control Unit ECU schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical Central control unit ( CCU) schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Joystick Wire harnesses - Electrical schematic frame 11 (55.100) Electro-hydraulic remote valve 1 control ( Wire harnesses - Electrical schematic frame 11 (55.100) EHR1) Electro-hydraulic remote valve 2 control ( Wire harnesses - Electrical schematic frame 11 (55.100) EHR2) Wire harnesses - Electrical ISOBUS controller ( TECU) schematic frame 12 (55.100) Main diagnostic plug Wire harnesses - Electrical schematic frame 11 (55.100) Electro-hydraulic remote valve diagnostic Wire harnesses - Electrical plug schematic frame 11 (55.100) Analogue digital instruments ( ADIC)

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Electrical systems - Harnesses and connectors

X-005

X-207

Line end resistance CAN

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Wire harnesses - Electrical schematic frame 12 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component Diagram 00 CONNECTOR C001 -Transmission Earth PIN WIRE NUMBER NUMBER 1 2 (BK)

CONNECTOR C001 - Transmission Earth CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-024 Roof cable connection X-056B

84176552

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Electrical systems - Harnesses and connectors

CONNECTOR C002 - Cab Earth PIN WIRE NUMBER NUMBER 1 2 (BK)

CONNECTOR C002 - Cab Earth CIRCUIT REFERENCE X-024 Roof cable connection X-056B

84176551

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

CONNECTOR X-001 - Main Harness/ Engine Connection CONNECTOR X-001 - Main Harness/ Engine Connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 2 1281 (BR/WH) 148 (BR/WH)

1279 (RD/GN) 42 (RD/GN)

4 5

269 (RD) 290 (RD)

272 (YE) 292 (YE)

299 (OR/BL) 300 (OR/BL)

357 (OR/WH) 470 (OR/WH)

361 (OR/BL) 634 (OR/BL)

10 11

1132 (WH) 542 (WH)

1145 (GY) 535 (GY)

1137 (GN) 538 (GN)

X-937EDC17 CONNECTOR 2 X-001Engine - Cab connection X-376Diagnostic Socket 1 X-001Main Harness/ Engine Connection X-001Main Harness/ Engine Connection X-460ADIC CN2 X-012ALTERNATOR D+ X-001Engine - Cab connection X-360Brake fluid level switch X-001Engine - Cab connection X-460ADIC CN2 X-001Main Harness/ Engine Connection X-357Engine Intake Air Filter X-001Engine - Cab connection X-460ADIC CN2 X-001Main Harness/ Engine Connection SP-029 X-001Main Harness/ Engine Connection X-360Brake fluid level switch X-001Engine - Cab connection X-042Filtro A/C X-001Engine - Cab connection X-001Main Harness/ Engine Connection X-050Main Harness/Roof Connection X-042Filtro A/C X-001Engine - Cab connection X-001Main Harness/ Engine Connection X-044Thermostat No Frost A/C X-001Main Harness/ Engine Connection X-050Main Harness/Roof Connection X-001Engine - Cab connection X-025Lights connection HOOD X-001Main Harness/ Engine Connection X-120Modulo Relays R9-R16 + Fuses F37-F40 X-001Engine - Cab connection X-025Lights connection HOOD X-120Modulo Relays R9-R16 + Fuses F37-F40 X-001Main Harness/ Engine Connection X-001Engine - Cab connection X-025Lights connection HOOD

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Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-001 - Main Harness/ Engine Connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 14 1138 (BL) 544 (BL)

469 (BL) 771 (BL)

1069 (YE) 979 (YE)

1043 (GN) 1068 (GN)

1277 (TQ/WH) 823 (BL/WH)

1004 (YE) 842 (YE)

1272 (BL/YE) 155 (BL/YE)

21 22 23 24

X-091Light Control SW X-001Main Harness/ Engine Connection X-001Engine - Cab connection X-025Lights connection HOOD X-050Main Harness/Roof Connection X-001Main Harness/ Engine Connection X-088A/C compressor X-001Engine - Cab connection X-001Engine - Cab connection X-937EDC17 CONNECTOR 2 SP-103H X-001Main Harness/ Engine Connection SP-103L X-001Main Harness/ Engine Connection X-001Engine - Cab connection X-937EDC17 CONNECTOR 2 X-001Main Harness/ Engine Connection X-450ADIC CN1 X-008BDS (Control) X-001Engine Cab connection SP-150 X-001Main Harness/ Engine Connection X-001Engine - Cab connection X-008BDS (Control) X-001Engine - Cab connection X-002 PDU connection SP-008 X-001Main Harness/ Engine Connection -

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Electrical systems - Harnesses and connectors

CONNECTOR X-001 - Main Harness/ Engine Connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 25 1007 (OR) 1196 (OR)

1000 (YE/RD) 580 (YE/RD)

1001 (YE/BK) 577 (YE/BK)

1178 (BL) 164 (BL) 33 (BL)

29 30 31

1248 (BK/YE) 1249 (GN)

32 33

1252 (RD/YE) 1255 (RD/YE)

1253 (RD/YE) 1254 (RD/YE)

SP-031 X-001Engine - Cab connection X-130Modulo Fuses F1-F32 X-001Main Harness/ Engine Connection X-346AFront PTO X-346Front PTO X-200XCM CN1-A X-001Main Harness/ Engine Connection X-346AFront PTO X-346Front PTO X-220XCM CN2 X-001Main Harness/ Engine Connection X-001Main Harness/ Engine Connection SP-074 X-203SWCD display X-180 main-isobus connection X-002 PDU connection X-001Engine - Cab connection X-110Modulo Relays R1-R8 + Fuses F33-F36 X-001Main Harness/ Engine Connection X-001Engine - Cab connection X-937EDC17 CONNECTOR 2 SP-086 X-001Engine - Cab connection SP-087 X-001Main Harness/ Engine Connection SP-086 X-001Engine - Cab connection SP-087 X-001Main Harness/ Engine Connection

84142902

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Electrical systems - Harnesses and connectors

MOIL12TR0358AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-002 - PDU connection PIN WIRE NUMBER NUMBER 1 1271 (BK) 26 (BK) 2 1272 (BL/YE) 25 (BL/YE)

1273 (BK/WH) 18 (BK/WH)

1274 (RD/YE) 20 (RD/YE)

1275 (RD/YE) 21 (RD/YE)

1276 (RD/BK) 22 (RD/BK)

23 (BL) 33 (BL)

41 (RD/YE) 840 (RD/YE)

1177 (GN/WH) 681 (GN/WH)

CONNECTOR X-002 - PDU connection CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical SP-004 X-002 PDU connection X-369CRPM +/- SW X-280GROUND schematic frame 01 (55.100) X-001Engine - Cab connection X-002 PDU connection X-007CAB Power Fuse X-370 Power Pdu-module connection X-937EDC17 CONNECTOR 2 X-002 PDU connection X-012Interconnect Transmission / Trailer Socket J-003Trailer Socket ISO X-937EDC17 CONNECTOR 2 X-002 PDU connection X-369CRPM +/- SW X-280GROUND X-937EDC17 CONNECTOR 2 X-002 PDU connection SP-003 X-002 PDU connection X-937EDC17 CONNECTOR 2 X-002PDU connection X-004FUSE ENGINE 2 X-002PDU connection X-005KAM FUSE X-002PDU connection X-002PDU connection X-001Engine - Cab connection X-002PDU connection X-011STARTER MOTOR 50 X-002PDU connection X-533ENGINE MAXI-RELAY MODULE SP-064 X-002PDU connection X-049FUSE ENGINE 3 X-002PDU connection -

87382925

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Electrical systems - Harnesses and connectors

MOIL12TR0359AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-003 - FUSE ENGINE 1 PIN WIRE NUMBER NUMBER 1 15 (RD) 2 19 (RD)

CONNECTOR X-003 - FUSE ENGINE 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-002 X-003FUSE ENGINE 1 X-003FUSE ENGINE 1 SP-003

84157160

MOIL13TR00071AA

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-004 - FUSE ENGINE 2 PIN WIRE NUMBER NUMBER 1 16 (RD/GN) 2 22 (RD/BK)

CONNECTOR X-004 - FUSE ENGINE 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-002 X-004FUSE ENGINE 2 X-004FUSE ENGINE 2 X-002PDU connection

84157160

MOIL13TR00072AA

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-005 - KAM FUSE PIN WIRE NUMBER NUMBER 1 23 (BL)

CONNECTOR X-005 - KAM FUSE CIRCUIT REFERENCE X-005KAM FUSE X-002PDU connection

84157160

MOIL13TR00073AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-006 - Glow Plugs Power Fuse CONNECTOR X-006 - Glow Plugs Power Fuse WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 24 (O/W)

X-938Glow Plugs X-006Glow Plugs Power Fuse

MOIL12TR0360AA

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-007 - CAB Power Fuse PIN WIRE NUMBER NUMBER 1 25 (R)

CONNECTOR X-007 - CAB Power Fuse CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-007CAB Power Fuse X-370 Power Wire harnesses - Electrical schematic frame 01 (55.100) Pdu-module connection

84128187

MOIL12TR0361AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-008 - BDS (Control) PIN WIRE NUMBER NUMBER 1 823 (BL/WH) 2 3 4

35 (BK) 789 (BK) 842 (YE)

CONNECTOR X-008 - BDS (Control) CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-008BDS (Control) X-001Engine Cab connection X-008BDS (Control) SP-004 X-008BDS (Control) SP-004 X-001Engine - Cab connection X-008BDS (Control)

87745968

MOIL13TR00074AA

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-009 - BDS PIN NUMBER A 2B 3B B 2B

WIRE NUMBER (B) (BK) (BK)

CONNECTOR X-009 - BDS CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

Wire harnesses - Electrical X-500+ Battery X-009BDS X-009BDS X-010STARTER MOTOR schematic frame 01 (55.100) X-500+ Battery X-009BDS

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 01 CONNECTOR X-010 - STARTER MOTOR PIN WIRE NUMBER NUMBER 1 2B (B) 3B (BK)

CONNECTOR X-010 - STARTER MOTOR CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-500+ Battery X-009BDS X-009BDS X-010STARTER MOTOR

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Electrical systems - Harnesses and connectors

CONNECTOR X-011 - STARTER MOTOR 50 CONNECTOR X-011 - STARTER MOTOR 50 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 41 (RD/YE)

X-002 PDU connection X-011STARTER MOTOR 50

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Electrical systems - Harnesses and connectors

CONNECTOR X-012 - Interconnect Transmission / Trailer Socket CONNECTOR X-012 - Interconnect Transmission / Trailer Socket WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 414 (G) 42 (RD/GN)

2 3

89 (B) 413 (V)

9 (M)

105 (R)

18 (N)

X-939EDC17 CONNECTOR 1 X-94162 pin FPT interface X-012ALTERNATOR D+ X-001Engine - Cab connection SP-007 X-017RH front headlamp X-939EDC17 CONNECTOR 1 X-94162 pin FPT interface X-012Interconnect Transmission / Trailer Socket J-003Trailer Socket ISO X-012Interconnect Transmission / Trailer Socket J-003Trailer Socket ISO X-012Interconnect Transmission / Trailer Socket J-003Trailer Socket ISO

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Electrical systems - Harnesses and connectors

CONNECTOR X-013 - Alternator PIN WIRE NUMBER NUMBER 1 150 (H) 822 (R)

154 (V)

222 (N)

223 (B)

5 6

225 (Z)

CONNECTOR X-013 - Alternator CIRCUIT REFERENCE SP-010 X-013Head-lamp/engine harness connection X-304STARTER MOTOR X-013Alternator SP-011 X-013Head-lamp/engine harness connection SP-007 X-013Head-lamp/engine harness connection SP-008 X-013Head-lamp/engine harness connection X-013Head-lamp/engine harness connection H-004AHorn

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

CONNECTOR X-014 - LH corner light PIN WIRE NUMBER NUMBER 1 214 (RD/BK) A B

461 (B) 463 (N)

CONNECTOR X-014 - LH corner light CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-001 X-014Fuse Engine Main Fuse SP-008 X-014LH corner light SP-007 X-014LH corner light

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Electrical systems - Harnesses and connectors

CONNECTOR X-015 - Corner light RH. PIN WIRE NUMBER NUMBER 1 543 (BL) A B

456 (B) 462 (N)

CONNECTOR X-015 - Corner light RH. CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-015Horn X-025Head-lamp/engine harness connection SP-008 X-015Corner light RH. SP-007 X-015Corner light RH.

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Electrical systems - Harnesses and connectors

CONNECTOR X-016 - LH front headlamp PIN NUMBER 1 A B C

CONNECTOR X-016 - LH front headlamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 524 (BK) 168 (H) 91 (N) 93 (V)

X-016Horn SP-046 X-016LH front headlamp SP-010 SP-007 X-016LH front headlamp SP-011 X-016LH front headlamp

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Electrical systems - Harnesses and connectors

CONNECTOR X-017 - RH front headlamp CONNECTOR X-017 - RH front headlamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER A 526 (WH) 95 (H) B 528 (BK) 89 (N) C 162 (V)

SP-047 X-017LH corner light SP-010 X-017RH front headlamp SP-046 X-017LH corner light SP-007 X-017RH front headlamp SP-011 X-017RH front headlamp

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Electrical systems - Harnesses and connectors

CONNECTOR X-018 - Corner light RH. PIN WIRE NUMBER NUMBER A 525 (WH) B 527 (BK)

CONNECTOR X-018 - Corner light RH. CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-047 X-018Corner light RH. SP-046 X-018Corner light RH.

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Electrical systems - Harnesses and connectors

CONNECTOR X-019 - LH front headlamp PIN NUMBER 1 2 3 4

CONNECTOR X-019 - LH front headlamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 530 (BK) 531 (GN) 534 (GY)

SP-046 X-019LH front headlamp SP-048 X-019LH front headlamp X-019LH front headlamp SP-049

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 02 CONNECTOR X-020 - RH front headlamp PIN NUMBER 1 2 3 4

WIRE NUMBER 529 (BK) 532 (GN) 533 (GY)

CONNECTOR X-020 - RH front headlamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-046 X-020RH front headlamp SP-048 X-020RH front headlamp SP-049 X-020RH front headlamp

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Wire harnesses - Electrical schematic frame 07 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-021 - LH Front Lamp PIN WIRE NUMBER NUMBER 1 1140 (YE/BK) 2 520 (BK) 3

560 (TQ/BK)

CONNECTOR X-021 - LH Front Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-042 X-021LH Front Lamp X-021LH Front Lamp X-403Roof Ground 2 X-021LH Front Lamp X-385Main Circuit Connection 2

82000579

MOIL12TR0374AA

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Wire harnesses - Electrical schematic frame 07 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-021A - LH Front Lamp PIN WIRE NUMBER NUMBER 2 378 (BK) 4

929 (RD/BK)

CONNECTOR X-021A - LH Front Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-021ALH Front Lamp X-403Roof Ground 2 X-021ALH Front Lamp SP-097

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Wire harnesses - Electrical schematic frame 07 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-022 - RH Front lamp PIN WIRE NUMBER NUMBER 1 562 (YE) 2

509 (BK)

556 (TQ)

CONNECTOR X-022 - RH Front lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-022RH Front lamp X-050Main Circuit Connection 1 X-022RH Front lamp X-403Roof Ground 2 X-022RH Front lamp X-050Main Circuit Connection 1

82000579

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Wire harnesses - Electrical schematic frame 07 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-022A - RH Front lamp PIN WIRE NUMBER NUMBER 2 522 (BK) 4

959 (RD/YE)

CONNECTOR X-022A - RH Front lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-022ARH Front lamp X-403Roof Ground 2 X-022ARH Front lamp SP-098

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Wire harnesses - Electrical schematic frame 07 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-023 - LH Rear Lamp PIN WIRE NUMBER NUMBER 1 550 (BK) 2 3 4

1077 (TQ/BK) 547 (YE) 747 (RD)

CONNECTOR X-023 - LH Rear Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-023LH Rear Lamp X-400Fuse Box Wire harnesses - Electrical Ground 1 schematic frame 07 (55.100) X-023LH Rear Lamp SP-050 X-023LH Rear Lamp SP-012 X-023LH Rear Lamp SP-069

87745334

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Electrical systems - Harnesses and connectors

CONNECTOR X-024 - Roof cable connection PIN WIRE NUMBER NUMBER 1 1 (RD) 521 (BK)

2 3 4

1076 (TQ) 2 (BK) 1141 (YE/BK) 746 (RD)

CONNECTOR X-024 - RH Rear Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical X-892Battery Negative Stud schematic frame 07 (55.100) X-893Boost Terminal Negative X-024RH Rear Lamp X-400Fuse Box Ground 1 X-024RH Rear Lamp SP-051 X-024Roof cable connection X-056B X-024RH Rear Lamp SP-058 SP-069 X-024RH Rear Lamp

87745334

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Electrical systems - Harnesses and connectors

CONNECTOR X-025 - Head-lamp/engine harness connection CONNECTOR X-025 - Head-lamp/engine harness connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 535 (GY) 536 (GY)

537 (GN) 538 (GN)

1033 (BK) 539 (BK)

541 (WH) 542 (WH)

2000 (BK) 206 (BK)

543 (BL) 544 (BL)

X-001Engine - Cab connection X-025Lights connection HOOD SP-049 X-025Head-lamp/engine harness connection SP-048 X-025Head-lamp/engine harness connection X-001Engine - Cab connection X-025Lights connection HOOD X-025Lights connection HOOD X-420ENGINE EARTH SP-046 X-025Head-lamp/engine harness connection SP-047 X-025Head-lamp/engine harness connection X-001Engine - Cab connection X-025Lights connection HOOD X-025Head-lamp/engine harness connection SP-046 X-025Lights connection HOOD X-420ENGINE EARTH X-015Horn X-025Head-lamp/engine harness connection X-001Engine - Cab connection X-025Lights connection HOOD

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Wire harnesses - Electrical schematic frame 07 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-026 - 8A Socket PIN WIRE NUMBER NUMBER 1 726 (BK) 2

1151 (TQ/WH)

CONNECTOR X-026 - 8A Socket CIRCUIT REFERENCE X-0268A Socket X-400Fuse Box Ground 1 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-0268A Socket

87691950

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 09 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-027 - Cigar Lighter Base CONNECTOR X-027 - Cigar Lighter Base WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 647 (BK) 2

1154 (GY/RD)

X-027Cigar Lighter Base X-400Fuse Wire harnesses - Electrical schematic frame 09 (55.100) Box Ground 1 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-027Cigar Lighter Base

87699736

MOIL12TR0380AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-029 - Electrical Seat PIN WIRE NUMBER NUMBER 1 727 (BK) 2

1152 (WH/BL)

CONNECTOR X-029 - Electrical Seat CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-029Electrical Seat X-400Fuse Box Wire harnesses - Electrical schematic frame 09 (55.100) Ground 1 X-029Electrical Seat SP-118

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MOIL12TR0381AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 03 CONNECTOR X-030 - Fan Speed SW PIN WIRE NUMBER NUMBER 1 452 (GN/GY) 2 354 (GY) 3

342 (TQ/WH)

349 (PK)

353 (RD)

CONNECTOR X-030 - Fan Speed SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-150 X-030Fan Speed SW X-030Fan Speed SW X-050Main Circuit Connection 1 X-030Fan Speed SW X-050Main Circuit Connection 1 X-030Fan Speed SW X-050Main Circuit Connection 1 X-030Fan Speed SW X-050Main Circuit Connection 1

MOIL12TR00930AA

MOIL12TR0382AA

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Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-031 - A/C SW PIN WIRE NUMBER NUMBER 1 454 (GN/GY) 2 437 (GN/BK) 4 451 (BK)

CONNECTOR X-031 - A/C SW CIRCUIT REFERENCE X-150 X-031A/C SW X-031A/C SW SP-027 X-031A/C SW X-403Roof Ground 2

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-032 - Beacon SW PIN WIRE NUMBER NUMBER 1 2 600 (RD/YE) 3 620 (OR/WH) 4 5 6

612 (RD/YE) 613 (OR/BK)

606 (BK)

8 9 10

619 (YE/BK) -

CONNECTOR X-032 - Beacon SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 08 (55.100) X-032Beacon SW SP-054 X-071RH Beacon Socket/ Extension X-032Beacon SW X-032Beacon SW SP-054 X-073LH Beacon Socket/ Extension X-032Beacon SW X-403Roof Ground 2 X-032Beacon SW SP-042 X-032Beacon SW -

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Electrical systems - Harnesses and connectors

CONNECTOR X-034 - Lights SW PIN WIRE NUMBER NUMBER 1 1232 (WH/BL) 2

4 (OR/WH)

3 4 5

236 (WH/RD) 1292 (VT/BK)

6 7 8 9 10

235 (WH/RD) 1238 (BK) 1287 (YE/BK) 3 (BK) 24 (YE/BK)

CONNECTOR X-034 - Lights SW CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

Wire harnesses - Electrical X-034Lights SW X-385Main Circuit schematic frame 22 (55.100) Connection 2 C93Speed Electric fan resistor SP-062 SP-013 X-034Lights SW X-034Lights SW X-385Main Circuit Connection 2 X-034Lights SW SP-013 X-034Lights SW X-403Roof Ground 2 SP-042 X-034Lights SW X-115BImplement Socket J-001 X-938Glow Plugs X-006Glow Plugs Power Fuse

84819781

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Electrical systems - Harnesses and connectors

CONNECTOR X-035B - Roof Work light connection CONNECTOR X-035B - Roof Work light connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 3 255 (H) 4

255 (H)

X-035BRoof Work light connection X-035BRoof Work light connection X-035BRoof Work light connection X-035BRoof Work light connection

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Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-035C - Roof Road+Work light connection CONNECTOR X-035C - Roof Road+Work light connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 348 (H) 2

409 (H)

410 (A)

409A (H)

410 (A)

X-035CRoof Road+Work light connection SP-1 X-939EDC17 CONNECTOR 1 X-94162 pin FPT interface X-939EDC17 CONNECTOR 1 X-94162 pin FPT interface X-035CRoof Road+Work light connection SP-1 X-939EDC17 CONNECTOR 1 X-94162 pin FPT interface

84153175

MOIL13TR00078AA

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Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-036 - Rear Wiper and Washer SW CONNECTOR X-036 - Rear Wiper and Washer SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 2 598 (GN/YE) 3

616 (OR/BL)

1241 (GN)

1211 (GN/BK)

870 (GN/YE)

604 (BK)

597 (YE/BK)

9 10

SP-055 X-036Rear Wiper and Washer SW X-036Rear Wiper and Washer SW X-050Main Circuit Connection 1 X-036Rear Wiper and Washer SW X-038Rear Wiper X-036Rear Wiper and Washer SW X-038Rear Wiper X-036Rear Wiper and Washer SW SP-055 X-403Roof Ground 2 X-036Rear Wiper and Washer SW SP-042 X-036Rear Wiper and Washer SW -

84819781

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Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-038 - Rear Wiper PIN WIRE NUMBER NUMBER 1 596 (BK) 2

1241 (GN)

3 4 5

1240 (GN/YE) 1211 (GN/BK)

CONNECTOR X-038 - Rear Wiper CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

X-038Rear Wiper X-403Roof Ground Wire harnesses - Electrical schematic frame 08 (55.100) 2 X-036Rear Wiper and Washer SW X-038Rear Wiper SP-055 X-038Rear Wiper X-036Rear Wiper and Washer SW X-038Rear Wiper -

87710588

MOIL12TR0390AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-039 - Radio PIN NUMBER A4 A7 A8 B3 B4 B5 B6

WIRE NUMBER 1155 (WH/GN) 1072 (TQ/WH) 644 (BK) 641 (TQ) 640 (TQ/BK) 642 (YE/BK) 643 (YE)

CONNECTOR X-039 - Radio CIRCUIT REFERENCE X-150 X-039Radio X-150 X-039Radio X-039Radio X-403Roof Ground 2 X-039Radio X-082RH Speaker 1 X-039Radio X-083RH Speaker 2 X-039Radio X-085LH Speaker 2 X-039Radio X-084LH Speaker 1

MOIL12TR00931AA

MOIL12TR0391AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 22 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 04 CONNECTOR X-040 - A/C SW LED PIN WIRE NUMBER NUMBER 1 455 (BK) 2 1564 (GN/BK)

CONNECTOR X-040 - A/C SW LED CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-007 H-004BHorn X-040A/C SW LED SP-027

84278792

MOIL12TR0392AA

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Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-041 - A/C Temperature Potentiometer CONNECTOR X-041 - A/C Temperature Potentiometer WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 358 (BL) 2

360 (GY)

X-041A/C Temperature Potentiometer Wire harnesses - Electrical schematic frame 05 (55.100) X-050Main Circuit Connection 1 X-041A/C Temperature Potentiometer X-050Main Circuit Connection 1

87493513

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Electrical systems - Harnesses and connectors

CONNECTOR X-042 - A/C Filter PIN WIRE NUMBER NUMBER 1 357 (OR/WH) 2

361 (OR/BL)

CONNECTOR X-042 - A/C Filter CIRCUIT REFERENCE X-042A/C Filter X-001Engine - Cab connection X-042Filtro A/C X-001Engine - Cab connection

82012083

MOIL12TR0394AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-043 - A/C Tap Actuator PIN WIRE NUMBER NUMBER 1 355 (WH/GN) 2 3

458 (OR) 459 (WH/RD)

460 (WH/BK)

462 (WH/BK)

CONNECTOR X-043 - A/C Tap Actuator CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-045A/C ECU X-043A/C Tap Actuator X-043A/C Tap Actuator SP-037 X-043A/C Tap Actuator X-045A/C ECU X-045A/C ECU X-043A/C Tap Actuator SP-007 X-015Corner light RH.

MOIL12TR00932AA

MOIL12TR0395AA

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Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-044 - Thermostat No Frost A/C CONNECTOR X-044 - Thermostat No Frost A/C WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 380 (GN/BK) 2

634 (OR/BL)

443 (BK)

X-044Thermostat No Frost A/C SP-105 X-001Main Harness/ Engine Connection X-044Thermostat No Frost A/C X-044Thermostat No Frost A/C X-410Steering Column Ground

84136442

MOIL12TR0396AA

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Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-045 - A/C ECU PIN WIRE NUMBER NUMBER 2 356 (OR) 3 457 (BK) 6 7

463 (BL) 460 (WH/BK)

459 (WH/RD)

9 13

462 (WH/BK) 464 (GY)

355 (WH/GN)

CONNECTOR X-045 - A/C ECU CIRCUIT REFERENCE X-045A/C ECU SP-037 X-045A/C ECU X-410Steering Column Ground SP-007 X-014LH corner light X-045A/C ECU X-043A/C Tap Actuator X-043A/C Tap Actuator X-045A/C ECU SP-007 X-015Corner light RH. X-045A/C ECU X-050Main Harness/Roof Connection X-045A/C ECU X-043A/C Tap Actuator

87694702

MOIL12TR0397AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-046 - LH Fan PIN WIRE NUMBER NUMBER 1 309 (GY) 2 346 (TQ/WH) 3 453 (BK) 4

445 (RD/BK)

351 (GN)

CONNECTOR X-046 - LH Fan CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

Wire harnesses - Electrical SP-032 X-046LH Fan schematic frame 05 (55.100) SP-033 X-046LH Fan X-400Fuse Box Ground 1 X-046LH Fan X-110Modulo Relays R1-R8 + Fuses F33-F36 X-046LH Fan X-110Modulo Relays R1-R8 + Fuses F33-F36 X-046LH Fan

MOIL12TR00933AA

MOIL12TR0398AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-047 - RH Fan PIN WIRE NUMBER NUMBER 1 308 (GY) 2 348 (TQ/WH) 3

449 (BK)

364 (WH)

352 (BR)

CONNECTOR X-047 - RH Fan CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

Wire harnesses - Electrical SP-032 X-047RH Fan schematic frame 05 (55.100) X-035CRoof Road+Work light connection SP-1 X-400Fuse Box Ground 1 X-047RH Fan X-110Modulo Relays R1-R8 + Fuses F33-F36 X-047RH Fan X-110Modulo Relays R1-R8 + Fuses F33-F36 X-047RH Fan

MOIL12TR00933AA

MOIL12TR0399AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-048 - Wiper Motor Timer CONNECTOR X-048 - Wiper Motor Timer WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1218 (BK) 2

1230 (YE)

3 4 5 6

1224 1225 1220 1231

(TQ/WH) (OR/BK) (GN) (GN/WH)

X-048Wiper Motor Timer X-410Steering Column Ground X-091Light Control SW X-048Wiper Motor Timer SP-045 X-048Wiper Motor Timer X-048Wiper Motor Timer SP-052 X-048Wiper Motor Timer SP-019 X-091Light Control SW X-048Wiper Motor Timer

87709659

MOIL13TR00079AA

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Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-049 - FUSE ENGINE 3 PIN WIRE NUMBER NUMBER 1 716 (RD/WH) 2 681 (GN/WH)

CONNECTOR X-049 - FUSE ENGINE 3 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-002 X-049FUSE ENGINE 3 X-049FUSE ENGINE 3 X-002PDU connection

84157160

MOIL13TR00080AA

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 05 CONNECTOR X-050 - Main Circuit Connection 1 CONNECTOR X-050 - Main Circuit Connection 1 PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER Wire harnesses - Electrical 1 310 (GY) SP-032 X-050Main Harness/Roof schematic frame 05 (55.100) Wire 354 (GY) Connection harnesses - Electrical schematic X-030Fan Speed SW X-050Main frame 06 (55.100) Wire harnesses Circuit Connection 1 - Electrical schematic frame 07 2 342 (TQ/WH) X-030Fan Speed SW X-050Main (55.100) Wire harnesses - Electrical 343 (TQ/WH) Circuit Connection 1 schematic frame 08 (55.100) SP-033 X-050Main Harness/Roof Connection 3 353 (RD) X-030Fan Speed SW X-050Main 447 (RD) Circuit Connection 1 X-050Main Harness/Roof Connection SP-035 4 271 (GN/BK) X-050Main Harness/Roof Connection 84 (GN/BK) SP-105 X-050Main Circuit Connection 1 SP-027 5 349 (PK) X-030Fan Speed SW X-050Main 350 (PK) Circuit Connection 1 SP-034 X-050Main Harness/Roof Connection 6 358 (BL) X-041A/C Temperature Potentiometer 463 (BL) X-050Main Circuit Connection 1 SP-007 X-014LH corner light 7 360 (GY) X-041A/C Temperature Potentiometer 464 (GY) X-050Main Circuit Connection 1 X-045A/C ECU X-050Main Harness/Roof Connection 8 440 (BL) X-150 X-050Main Circuit Connection 469 (BL) 1 X-050Main Harness/Roof Connection X-001Main Harness/ Engine Connection 9 439 (OR/WH) X-150 X-050Main Circuit Connection 470 (OR/WH) 1 X-001Main Harness/ Engine Connection X-050Main Harness/Roof Connection 10 X-130Modulo Fuses F1-F32 1134 (OR/WH) X-050Main Harness/Roof Connection 516 (OR/WH) X-050Main Circuit Connection 1 SP-043

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Electrical systems - Harnesses and connectors

CONNECTOR X-050 - Main Circuit Connection 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 11 1146 (GY/BK) 590 (GY/BK)

562 (YE) 563 (YE)

1301 (OR/BK) 621 (OR/BK)

1132 (WH) 504 (WH)

1300 (TQ/BK) 505 (TQ/BK)

485 (GN/WH) 486 (GN/WH)

615 (OR/BL) 616 (OR/BL)

1216 (BL/YE) 1217 (BL/YE)

1147 (GN/BK) 592 (GN/BK)

1035 (TQ) 556 (TQ)

X-063Roof Light Connection X-050Main Circuit Connection 1 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-050Main Harness/Roof Connection X-022RH Front lamp X-050Main Circuit Connection 1 SP-012 X-050Main Harness/Roof Connection SP-052 X-050Main Harness/Roof Connection X-050Main Circuit Connection 1 X-075Front Wiper Motor Openable X-001Main Harness/ Engine Connection X-050Main Harness/Roof Connection X-065Work lamp Switch X-050Main Circuit Connection 1 SP-120 X-050Main Harness/Roof Connection X-061Change Over SW X-050Main Circuit Connection 1 X-050Main Harness/Roof Connection SP-172 SP-044 X-050Main Circuit Connection 1 X-077Rear Wiper Washer Pump X-050Main Harness/Roof Connection X-036Rear Wiper and Washer SW X-050Main Circuit Connection 1 SP-015 X-050Main Harness/Roof Connection X-075Front Wiper Motor Openable X-050Main Circuit Connection 1 X-063Roof Light Connection X-050Main Circuit Connection 1 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-050Main Harness/Roof Connection SP-051 X-050Main Harness/Roof Connection X-022RH Front lamp X-050Main Circuit Connection 1

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

CONNECTOR X-051 - Roof Lamp 1 PIN WIRE NUMBER NUMBER 1 1127 (RD/YE)

CONNECTOR X-051 - Roof Lamp 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-051Roof Lamp 1 SP-054

87691425

MOIL12TR0403AA

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Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-052 - Roof Lamp 2 PIN WIRE NUMBER NUMBER 1 473 (BK)

CONNECTOR X-052 - Roof Lamp 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-052Roof Lamp 2 X-403Roof Ground 2

87691425

MOIL12TR0404AA

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Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-053 - Roof Lamp 3 PIN WIRE NUMBER NUMBER 1 487 (GY)

CONNECTOR X-053 - Roof Lamp 3 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-053Roof Lamp 3 X-064Door switch Wire harnesses - Electrical schematic frame 06 (55.100)

87691425

MOIL12TR0405AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-054 - Spot Lamp PIN WIRE NUMBER NUMBER 1 502 (YE/BK) 2 499 (BK)

CONNECTOR X-054 - Spot Lamp CIRCUIT REFERENCE X-054Spot Lamp SP-042 X-403Roof Ground 2 X-054Spot Lamp

87691950

MOIL12TR0406AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-055 - RH Rear Work Lamp CONNECTOR X-055 - RH Rear Work Lamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 483 (TQ/WH) 2 475 (BK)

Wire harnesses - Electrical X-055RH Rear Work Lamp SP-039 X-403Roof Ground 2 X-055RH Rear schematic frame 06 (55.100) Work Lamp

82012083

MOIL12TR0407AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-056 - LH Rear Work Lamp CONNECTOR X-056 - LH Rear Work Lamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 478 (TQ/WH) 7 (N) 2 476 (BK) 6 (AG)

Wire harnesses - Electrical SP-039 X-056LH Rear Work Lamp schematic frame 06 (55.100) X-056Electric fan X-0467 X-056LH Rear Work Lamp X-403Roof Ground 2 X-056Electric fan SP-062

82012083

MOIL12TR0408AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-056RH - RH Fan Motor PIN WIRE NUMBER NUMBER 1 3004 (RD) 2

3009 (TQ/YE)

CONNECTOR X-056RH - RH Fan Motor CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-047 Main cable connection X-056RH SP-062Electric Fan X-056RH

84335034

MOIL12TR0410AA

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Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-056LH - LH Fan Motor PIN WIRE NUMBER NUMBER 1 3003 (BK) 2

3008 (TQ/YE)

CONNECTOR X-056LH - LH Fan Motor CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-046 Main cable connection X-056LH SP-062Electric Fan X-056LH

84335034

MOIL12TR0409AA

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Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-057 - RH Front Roof Lamp CONNECTOR X-057 - RH Front Roof Lamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 482 (GY) 2 474 (BK)

SP-040 X-057RH Front Roof Lamp X-057RH Front Roof Lamp X-403Roof Ground 2

82012083

MOIL13TR00081AA

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Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-058 - LH Front Roof Lamp CONNECTOR X-058 - LH Front Roof Lamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 484 (GY) 2 477 (BK)

Wire harnesses - Electrical X-058LH Front Roof Lamp SP-040 X-058LH Front Roof Lamp X-403Roof schematic frame 06 (55.100) Ground 2

82012083

MOIL13TR00082AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-059 - RH Grab Rail Work Lamp CONNECTOR X-059 - RH Grab Rail Work Lamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 512 (TQ/GN) 2

511 (BK)

Wire harnesses - Electrical X-059RH Grab Rail Work Lamp schematic frame 06 (55.100) SP-041 X-403Roof Ground 2 X-059RH Grab Rail Work Lamp

84152155

MOIL13TR00083AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 06 CONNECTOR X-060 - LH Grab Rail Work Lamp CONNECTOR X-060 - LH Grab Rail Work PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 514 (TQ/GN) X-060LH Grab Rail Work Lamp SP-041 2 510 (BK) X-403Roof Ground 2 X-060LH Grab Rail Work Lamp

84152155

MOIL13TR00084AA

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Lamp ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-061 - Change Over SW PIN WIRE NUMBER NUMBER 1 2 490 (YE/BK) 3 505 (TQ/BK) 4 5 6 7

494 (BK)

8 9 10

492 (YE/BK) -

CONNECTOR X-061 - Change Over SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-061Change Over SW SP-042 X-061Change Over SW X-050Main Circuit Connection 1 X-061Change Over SW X-403Roof Ground 2 SP-042 X-061Change Over SW -

84819781

MOIL12TR0415AA

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Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-063 - Roof Light Connection CONNECTOR X-063 - Roof Light Connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1147 (GN/BK) 2

1146 (GY/BK)

3 4 5

1128 (TQ/GN) 495 (GY) 513 (TQ/GN)

Wire harnesses - Electrical X-063Roof Light Connection schematic frame 06 (55.100) X-050Main Circuit Connection 1 X-063Roof Light Connection X-050Main Circuit Connection 1 X-150 SP-040 X-063Roof Light Connection SP-040 X-063Roof Light Connection SP-041

84253498

MOIL13TR00085AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-064 - Door switch PIN WIRE NUMBER NUMBER 1 487 (GY)

CONNECTOR X-064 - Door switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-053Roof Lamp 3 X-064Door switch Wire harnesses - Electrical schematic frame 06 (55.100)

87705127

MOIL12TR0417AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-065 - Work lamp Switch PIN NUMBER 1 2 4 5 6

WIRE NUMBER 500 (YE/BK) 1131 (WH/YE) 515 (OR/WH) 488 (GN/WH) 504 (WH)

CONNECTOR X-065 - Work lamp Switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-065Work lamp Switch SP-042 X-065Work lamp Switch X-150 X-065Work lamp Switch SP-043 X-065Work lamp Switch SP-044 X-065Work lamp Switch X-050Main Circuit Connection 1

87697775

MOIL13TR00086AA

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Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 07 CONNECTOR X-071 - RH Beacon Socket/ Extension CONNECTOR X-071 - RH Beacon Socket/ Extension PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER Wire harnesses - Electrical 1 601 (BK) X-403Roof Ground 2 X-071RH schematic frame 08 (55.100) Beacon Socket/ Extension 2 620 (OR/WH) X-071RH Beacon Socket/ Extension X-032Beacon SW

87699736

MOIL12TR0419AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-073 - LH Beacon Socket/ Extension CONNECTOR X-073 - LH Beacon Socket/ Extension WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 611 (BK) 2

613 (OR/BK)

X-403Roof Ground 2 X-073LH Beacon Socket/ Extension X-073LH Beacon Socket/ Extension X-032Beacon SW

87699736

MOIL12TR0420AA

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Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-074 - Front Wiper Motor Fixed CONNECTOR X-074 - Front Wiper Motor Fixed WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 626 (BK) 2

1219 (GN)

1228 (OR/BK)

4 5

622 (BL)

1215 (BL/YE)

X-410Steering Column Ground X-074Front Wiper Motor Fixed SP-019 X-074Front Wiper Motor Fixed SP-052 X-074Front Wiper Motor Fixed SP-056 X-074Front Wiper Motor Fixed SP-015 X-074Front Wiper Motor Fixed

87710588

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Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-075 - Front Wiper Motor Openable CONNECTOR X-075 - Front Wiper Motor Openable WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 599 (BK) 9 (BK)

1222 (GN) 8 (GN)

12 (OR/BK) 621 (OR/BK)

4 5

5 (BL) 624 (BL)

1217 (BL/YE) 7 (BL/YE)

X-075Front Wiper Motor Openable X-403Roof Ground 2 X-012Interconnect Transmission / Trailer Socket J-003Trailer Socket ISO X-075Front Wiper Motor Openable X-385Main Circuit Connection 2 X-075A X-075 X-075A X-075 X-050Main Circuit Connection 1 X-075Front Wiper Motor Openable SP-062 X-0467 X-075Front Wiper Motor Openable X-385Main Circuit Connection 2 X-075Front Wiper Motor Openable X-050Main Circuit Connection 1 X-056Electric fan X-0467

87710588

MOIL12TR0421AA

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Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-075A - X-075A PIN WIRE NUMBER NUMBER 1 9 (BK)

2 3 4 5 6

8 (GN) 12 (OR/BK) 5 (BL) 7 (BL/YE)

CONNECTOR X-075A - X-075A CIRCUIT REFERENCE X-012Interconnect Transmission / Trailer Socket J-003Trailer Socket ISO X-075A X-075 X-075A X-075 SP-062 X-0467 X-056Electric fan X-0467

87710588

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-076 - Front Wiper Washer Pump CONNECTOR X-076 - Front Wiper Washer Pump WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 636 (BK) 2

617 (TQ/WH)

X-076Front Wiper Washer Pump X-400Fuse Box Ground 1 X-076Front Wiper Washer Pump SP-045

82944110

MOIL12TR0422AA

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Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-077 - Rear Wiper Washer Pump CONNECTOR X-077 - Rear Wiper Washer Pump WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 639 (BK) 2

615 (OR/BL)

X-400Fuse Box Ground 1 X-077Rear Wire harnesses - Electrical schematic frame 08 (55.100) Wiper Washer Pump X-077Rear Wiper Washer Pump X-050Main Harness/Roof Connection

82944110

MOIL12TR0423AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-078 - 25A Socket 1 PIN WIRE NUMBER NUMBER 1 1153 (BR)

CONNECTOR X-078 - 25A Socket 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-07825A Socket 1 SP-017

87705127

MOIL12TR0424AA

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Wire harnesses - Electrical schematic frame 09 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-079 - 25A Socket 2 PIN WIRE NUMBER NUMBER 1 173 (BK)

CONNECTOR X-079 - 25A Socket 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-07925A Socket 2 SP-026

87705127

MOIL12TR0425AA

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Wire harnesses - Electrical schematic frame 09 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 08 CONNECTOR X-080 - Cigar Lighter Base Lamp CONNECTOR X-080 - Cigar Lighter Base PIN WIRE NUMBER CIRCUIT REFERENCE NUMBER 1 651 (YE/BK) X-080Cigar Lighter Base Lamp SP-058

87705127

MOIL12TR0426AA

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Lamp ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 09 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-082 - RH Speaker 1 PIN WIRE NUMBER NUMBER 1 641 (TQ)

CONNECTOR X-082 - RH Speaker 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-039Radio X-082RH Speaker 1

87705127

MOIL12TR0427AA

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Wire harnesses - Electrical schematic frame 22 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-083 - RH Speaker 2 PIN WIRE NUMBER NUMBER 1 640 (TQ/BK)

CONNECTOR X-083 - RH Speaker 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-039Radio X-083RH Speaker 2

87691425

MOIL12TR0428AA

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Wire harnesses - Electrical schematic frame 22 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-084 - LH Speaker 1 PIN WIRE NUMBER NUMBER 1 643 (YE)

CONNECTOR X-084 - LH Speaker 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-039Radio X-084LH Speaker 1

87705127

MOIL12TR0429AA

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Wire harnesses - Electrical schematic frame 22 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-085 - LH Speaker 2 PIN WIRE NUMBER NUMBER 1 642 (YE/BK)

CONNECTOR X-085 - LH Speaker 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-039Radio X-085LH Speaker 2

87691425

MOIL12TR0430AA

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Wire harnesses - Electrical schematic frame 22 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-086 - 3rd Distributor SW CONNECTOR X-086 - 3rd Distributor SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 760 (YE/GN) 2

1170 (BK)

X-110Modulo Relays R1-R8 + Fuses Wire harnesses - Electrical schematic frame 10 (55.100) F33-F36 X-0863rd Distributor SW X-0863rd Distributor SW SP-022

87679493

MOIL12TR0431AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-087 - 3rd distributor solenoid disposition CONNECTOR X-087 - 3rd distributor solenoid disposition WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 177 (YE/BL) 754 (Y/U)

1265 (B) 1266 (BK)

Wire harnesses - Electrical X-110Modulo Relays R1-R8 + Fuses F33-F36 X-0873rd Distributor schematic frame 10 (55.100) Solenoid Disposition X-0893rd distributor solenoid X-0873rd distributor solenoid disposition X-0873rd distributor solenoid disposition X-0893rd distributor solenoid X-280GROUND X-0873rd Distributor Solenoid Disposition

87679493

MOIL12TR00165AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-088 - A/C compressor PIN WIRE NUMBER NUMBER 1 771 (BL) 2

576 (BK)

CONNECTOR X-088 - A/C compressor CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-088A/C compressor X-001Engine Wire harnesses - Electrical schematic frame 05 (55.100) - Cab connection X-088A/C compressor X-420ENGINE EARTH

82012083

MOIL12TR0432AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-089 - 3rd distributor solenoid CONNECTOR X-089 - 3rd distributor solenoid WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 754 (Y/U)

1265 (B)

X-0893rd distributor solenoid X-0873rd distributor solenoid disposition X-0873rd distributor solenoid disposition X-0893rd distributor solenoid

82012083

MOIL12TR00166AA

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Wire harnesses - Electrical schematic frame 10 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 09 CONNECTOR C93 - Speed Electric fan resistor CONNECTOR C93 - Speed Electric fan resistor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 1 (C) X-892Battery Negative Stud X-893Boost Terminal Negative 2 2 (RG) X-024Roof cable connectionX-056B 3 3 (RB) X-115BImplement Socket J-001 4 4 (AG) C93Speed Electric fan resistor SP-062

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Electrical systems - Harnesses and connectors

CONNECTOR X-090 - Flasher PIN WIRE NUMBER NUMBER A1 945 (RD) A2 953 (RD/YE) A3 31 (GN) A4 A5

1303 (RD/BK) 157 (YE)

A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8

947 (BR/GN) 1263 (OR/WH) 941 (WH/BL) 944 (RD) 919 (TQ) 918 (TQ/BK) 985 (WH/RD) 1250 (OR/BK) 952 (TQ/BK) 951 (TQ) 950 (BK)

C1 C2 C3 C4 C5 C6 C7 C8

CONNECTOR X-090 - Flasher CIRCUIT REFERENCE X-090Flasher SP-065 X-090Flasher SP-051A X-090Flasher X-098Main/ 7 Pole Socket Extension X-090Flasher SP-050A X-090Flasher X-098Main/ 7 Pole Socket Extension X-090Flasher X-092Hazard SW X-090Flasher X-450ADIC CN1 X-090Flasher SP-066 X-090Flasher SP-065 X-091Light Control SW X-090Flasher X-091Light Control SW X-090Flasher X-090Flasher SP-167 X-090Flasher X-450ADIC CN1 X-090Flasher SP-050 X-090Flasher SP-051 X-090Flasher X-400Fuse Box Ground 1 -

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

CONNECTOR X-091 - Light Control SW PIN NUMBER 1 2 3 4

WIRE NUMBER 1214 1223 1227 1259

1242 (GY)

6 7

174 (GN) 1138 (BL)

8 9 10 11 12

918 (TQ/BK) 919 (TQ) 169 (WH/BL) 623 (BL) 1231 (GN/WH)

1230 (YE)

(BL/YE) (TQ/WH) (OR/BK) (WH/BL)

CONNECTOR X-091 - Light Control SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-091Light Control SW SP-015 X-091Light Control SW SP-045 SP-052 X-091Light Control SW X-091Light Control SW X-385Main Harness/ Roof Connection X-120Modulo Relays R9-R16 + Fuses F37-F40 X-091Light Control SW SP-100 X-091Light Control SW X-091Light Control SW X-001Main Harness/ Engine Connection X-091Light Control SW X-090Flasher X-091Light Control SW X-090Flasher X-091Light Control SW SP-066 X-091Light Control SW SP-056 X-091Light Control SW X-048Wiper Motor Timer X-091Light Control SW X-048Wiper Motor Timer

87691878

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Electrical systems - Harnesses and connectors

CONNECTOR X-092 - Hazard SW PIN NUMBER 2 3 6 7

WIRE NUMBER 946 948 947 949

(RD) (WH/RD) (BR/GN) (BK)

CONNECTOR X-092 - Hazard SW CIRCUIT REFERENCE SP-065 X-092Hazard SW X-092Hazard SW SP-167 X-090Flasher X-092Hazard SW X-092Hazard SW X-410Steering Column Ground

84289727

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

CONNECTOR X-093 - LH Stop PIN NUMBER 1 2 3 4

WIRE NUMBER 729 (BR) 705 (OR) 1171 (RD) 1280 (BL/WH)

CONNECTOR X-093 - LH Stop CIRCUIT REFERENCE SP-018 X-093LH Stop SP-067 X-093LH Stop X-093LH Stop SP-069 X-093LH Stop X-210XCM CN1-B

87687242

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

CONNECTOR X-094 - RH Stop PIN NUMBER 1 2 3 4

WIRE NUMBER 742 (BR) 734 (OR) 1167 (RD) 1168 (BL/YE)

CONNECTOR X-094 - RH Stop CIRCUIT REFERENCE X-094RH Stop SP-018 X-094RH Stop SP-067 X-094RH Stop SP-069 X-210XCM CN1-B X-094RH Stop

87687242

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

CONNECTOR X-095 - Italian Licence Plate Splt Connector (trim sx) CONNECTOR X-095 - Italian Licence Plate Splt Connector (trim sx) WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1109 (YE) 1139 (YE)

1110 (BK) 1169 (BK)

X-095ALicense plate light X-095Italian Licence Plate Splt Connector (trim sx) SP-012 X-095Italian Licence Plate Splt Connector X-095ALicense plate light X-095Italian Licence Plate Splt Connector (trim sx) SP-022 X-095Italian Licence Plate Splt Connector

87736475

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Electrical systems - Harnesses and connectors

CONNECTOR X-095A - License plate light PIN WIRE NUMBER NUMBER 1 1109 (YE)

1110 (BK)

CONNECTOR X-095A - luce targa CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-095ALicense plate light X-095Italian Licence Plate Splt Connector (trim sx) X-095ALicense plate light X-095Italian Licence Plate Splt Connector (trim sx)

82012083

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Electrical systems - Harnesses and connectors

CONNECTOR X-096 - LH License Plate Lamp CONNECTOR X-096 - LH License Plate Lamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 752 (YE/BK) 2 762 (BK)

SP-042 X-096LH License Plate Lamp X-096LH License Plate Lamp X-403Roof Ground 2

84152155

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Electrical systems - Harnesses and connectors

CONNECTOR X-097 - RH License Plate Lamp CONNECTOR X-097 - RH License Plate Lamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 753 (YE/BK) 2 763 (BK)

SP-042 X-097RH License Plate Lamp X-097RH License Plate Lamp X-403Roof Ground 2

84152155

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Electrical systems - Harnesses and connectors

CONNECTOR X-098 - Trailer socket PIN WIRE NUMBER NUMBER 1 157 (YE) 566 (Y)

569 (BK) 717 (W)

31 (GN) 732 (G)

1163 (YE/BK) 731 (N)

1172 (RD) 730 (R)

1162 (YE) 733 (B)

CONNECTOR X-098 - Trailer socket CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-090Flasher X-098Main/ 7 Pole Socket Extension X-098Trailer socket X-099Trailer Socket NAR X-098Main/ 7 Pole Socket Extension X-410Steering Column Ground X-099Trailer Socket NAR X-098Trailer socket X-090Flasher X-098Main/ 7 Pole Socket Extension X-098Trailer socket X-099Trailer Socket NAR X-098Main/ 7 Pole Socket Extension SP-058 X-098Trailer socket X-099Trailer Socket NAR SP-069 X-098Main/ 7 Pole Socket Extension X-098Trailer socket X-099Trailer Socket NAR X-098Main/ 7 Pole Socket Extension X-130Modulo Fuses F1-F32 X-098Trailer socket X-099Trailer Socket NAR

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Electrical systems - Harnesses and connectors

CONNECTOR X-099 - Trailer Socket NAR CONNECTOR X-099 - Trailer Socket NAR WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 717 (W) 2

733 (B)

566 (Y)

730 (R)

732 (G)

731 (N)

X-099Trailer Socket NAR X-098Trailer socket X-098Trailer socket X-099Trailer Socket NAR X-098Trailer socket X-099Trailer Socket NAR X-098Trailer socket X-099Trailer Socket NAR X-098Trailer socket X-099Trailer Socket NAR X-098Trailer socket X-099Trailer Socket NAR

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 10 CONNECTOR X-100 - Main harness/armrest connection CONNECTOR X-100 - Main harness/armrest connection PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER A1 Wire harnesses - Electrical 185 (TQ/BK) X-220XCM CN2 X-100Main schematic frame 04 (55.100) Wire harness/armrest connection A2 237 (BK/YE) SP-068 X-100Main harness/armrest harnesses - Electrical schematic frame 11 (55.100) connection A3 A4 A5 262 (WH) X-240XCM CN3-B X-100Main harness/armrest connection A6 A7 A8 27 (BK/WH) SP-009 X-100Main harness/armrest connection B1 193 (TQ/GN) X-220XCM CN2 X-100Main harness/armrest connection B2 B3 B4 B5 B6 B7 B8 C1 1053 (TQ/WH) SP-006 X-100Main harness/armrest connection C2 558 (BK/YE) X-100Main harness/armrest connection SP-068 C3 719 (BK) X-400Fuse Box Ground 1 X-100Main harness/armrest connection C4 276 (RD) SP-202H X-100Main harness/armrest connection C5 497 (BL) SP-202L X-100Main harness/armrest connection C6 557 (BK/YE) SP-068 X-100Main harness/armrest connection C7 230 (YE/GN) X-210XCM CN1-B X-100Main harness/armrest connection C8 194 (TQ) X-230XCM CN3-A X-100Main harness/armrest connection

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Electrical systems - Harnesses and connectors

MOIL12TR00167AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 11 CONNECTOR X-110 - Modulo Relays R1-R8 + Fuses F33-F36 CONNECTOR X-110 - Modulo Relays R1-R8 + Fuses F33-F36 PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 33A 663 (BL) SP-025 X-110Modulo Relays R1-R8 Wire harnesses - Electrical schematic frame 02 (55.100) Wire + Fuses F33-F36 33B X-110Modulo Relays R1-R8 + Fuses harnesses - Electrical schematic 1154 (GY/RD) frame 05 (55.100) Wire harnesses F33-F36 X-027Cigar Lighter Base 34A 817 (BR) SP-070 X-110Modulo Relays R1-R8 - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical + Fuses F33-F36 schematic frame 18 (55.100) Wire 34B X-110Modulo Relays R1-R8 + 818 (RD/BK) Fuses F33-F36 X-180MAIN-ISOBUS harnesses - Electrical schematic frame 20 (55.100) Connector 35A 712 (BR) SP-070 X-110Modulo Relays R1-R8 + Fuses F33-F36 35B X-110Modulo Relays R1-R8 + Fuses 1165 (OR/BK) F33-F36 SP-052 36A 677 (BL) SP-025 X-110Modulo Relays R1-R8 + Fuses F33-F36 36B X-110Modulo Relays R1-R8 + Fuses 1261 (VT/BK) F33-F36 X-385Main Harness/ Roof Connection R1_30 572 (BL) SP-025 X-110Modulo Relays R1-R8 + Fuses F33-F36 R1_85 X-110Modulo Relays R1-R8 + Fuses 283 (BK) F33-F36 SP-023 R1_86 1173 (BR) SP-070 X-110Modulo Relays R1-R8 + Fuses F33-F36 R1_87 X-110Modulo Relays R1-R8 + Fuses 1176 (BR) F33-F36 SP-072 R2_30 X-110Modulo Relays R1-R8 + Fuses 570 (BL) F33-F36 SP-025 R2_85 X-110Modulo Relays R1-R8 + Fuses 571 (BK) F33-F36 SP-023 R2_86 X-110Modulo Relays R1-R8 + Fuses 1258 (WH/RD) F33-F36 X-385Main Harness/ Roof Connection R2_87 X-110Modulo Relays R1-R8 + Fuses 1160 (WH) F33-F36 SP-071 R3_30 X-130Modulo Fuses F1-F32 1244 (RD) X-110Modulo Relays R1-R8 + Fuses F33-F36 R3_85 X-110Modulo Relays R1-R8 + Fuses 1248 (BK/YE) F33-F36 X-001Main Harness/ Engine Connection R3_86 X-110Modulo Relays R1-R8 + Fuses 1289 (BR) F33-F36 SP-070 R3_87 X-110Modulo Relays R1-R8 + Fuses 1246 (RD/YE) F33-F36 SP-087 R4_30 X-130Modulo Fuses F1-F32 466 (BL) X-110Modulo Relays R1-R8 + Fuses F33-F36

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Electrical systems - Harnesses and connectors

CONNECTOR X-110 - Modulo Relays R1-R8 + Fuses F33-F36 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER R4_85 367 (BK) R4_86

467 (PK)

R4_87

351 (GN)

R5_30

448 (BL)

R5_85

368 (BK)

R5_86

468 (PK)

R5_87

352 (BR)

R6_30

372 (BL)

R6_85

442 (BK)

R6_86

370 (RD)

R6_87

445 (RD/BK)

R7_30

373 (BL)

R7_85

362 (BK)

R7_86

371 (RD)

R7_87

364 (WH)

R8_30

756 (BR/GY)

R8_85

760 (YE/GN)

R8_86

758 (BR/GY)

R8_87

177 (YE/BL)

X-110Modulo Relays R1-R8 + Fuses F33-F36 SP-023 SP-034 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-046LH Fan X-130Modulo Fuses F1-F32 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-110Modulo Relays R1-R8 + Fuses F33-F36 SP-023 SP-034 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-047RH Fan X-130Modulo Fuses F1-F32 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-110Modulo Relays R1-R8 + Fuses F33-F36 SP-023 X-110Modulo Relays R1-R8 + Fuses F33-F36 SP-035 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-046LH Fan X-130Modulo Fuses F1-F32 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-110Modulo Relays R1-R8 + Fuses F33-F36 SP-023 SP-035 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-047RH Fan X-110Modulo Relays R1-R8 + Fuses F33-F36 SP-119 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-0863rd Distributor SW X-110Modulo Relays R1-R8 + Fuses F33-F36 SP-119 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-0873rd Distributor Solenoid Disposition

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Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100)

Electrical systems - Harnesses and connectors

MOIL13TR00088AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-115A - Implement Socket CONNECTOR X-115A - Implement Socket WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 2 (BR) 2 1 (YE)

X-024Roof cable connection X-056B X-892Battery Negative Stud X-893Boost Terminal Negative

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Electrical systems - Harnesses and connectors

CONNECTOR X-115B - Implement Socket CONNECTOR X-115B - Implement Socket WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 3 (BK)

X-115BImplement Socket J-001

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 12 CONNECTOR X-120 - Modulo Relays R9-R16 + Fuses F37-F40 CONNECTOR X-120 - Modulo Relays R9-R16 + Fuses F37-F40 PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 37A X-120Modulo Relays R9-R16 + Wire harnesses - Electrical 674 (BL) Fuses F37-F40 SP-025 schematic frame 02 (55.100) Wire harnesses - Electrical schematic 37B X-120Modulo Relays R9-R16 + 1151 (TQ/WH) frame 15 (55.100) Wire harnesses Fuses F37-F40 X-0268A Socket 38A 1044 (BL) SP-025 X-120Modulo Relays R9-R16 - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical + Fuses F37-F40 schematic frame 23 (55.100) 38B X-120Modulo Relays R9-R16 + 1045 (RD/G) Fuses F37-F40 X-180MAIN-ISOBUS Connector 39A X-120Modulo Relays R9-R16 + 1175 (BR) Fuses F37-F40 SP-070 39B 692 (OR) SP-073 X-120Modulo Relays R9-R16 + Fuses F37-F40 40A 802 (BR) SP-070 X-120Modulo Relays R9-R16 + Fuses F37-F40 40B X-120Modulo Relays R9-R16 + 1299 (BK/YE) Fuses F37-F40 SP-068 R10_30 X-130Modulo Fuses F1-F32 1143 (OR) X-120Modulo Relays R9-R16 + Fuses F37-F40 R10_85 567 (BK) SP-023 X-120Modulo Relays R9-R16 + Fuses F37-F40 R10_86 X-120Modulo Relays R9-R16 + 1242 (GY) Fuses F37-F40 X-091Light Control SW R10_87 X-120Modulo Relays R9-R16 + 583 (GY/WH) Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 R11_30 X-130Modulo Fuses F1-F32 1142 (OR/WH) X-120Modulo Relays R9-R16 + Fuses F37-F40 R11_85 X-120Modulo Relays R9-R16 + 575 (BK) Fuses F37-F40 SP-023 R11_86 X-120Modulo Relays R9-R16 + 1600 (GN) Fuses F37-F40 SP-100 R11_87 X-120Modulo Relays R9-R16 + 997 (GN/WH) Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 R12_30 X-120Modulo Relays R9-R16 + 583 (GY/WH) Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 R12_85 584 (BK) SP-023 X-120Modulo Relays R9-R16 + Fuses F37-F40 R12_86 X-120Modulo Relays R9-R16 + 585 (TQ/BK) Fuses F37-F40 SP-120

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Electrical systems - Harnesses and connectors

CONNECTOR X-120 - Modulo Relays R9-R16 + Fuses F37-F40 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER R12_87A 1145 (GY)

R12_87

590 (GY/BK)

R13_30

997 (GN/WH)

R13_85

581 (BK)

R13_86

586 (TQ/BK)

R13_87A

1137 (GN)

R13_87

592 (GN/BK)

R14_30

593 (OR/BK)

R14_85

253 (WH/BK)

R14_86

247 (OR/WH)

R14_87

711 (GN/WH)

R15_30

594 (OR/BL)

R15_85

782 (TQ/BK)

R15_86

233 (OR/WH)

R15_87

713 (GY)

R16_30

595 (OR/WH)

R16_85

797 (BK/YE)

R16_86

798 (OR/WH)

R16_87

714 (BL)

R9_30

1164 (WH/BL)

R9_85

83 (WH)

R9_86

1284 (WH/BL)

R9_87

1262 (BL/YE)

X-001Main Harness/ Engine Connection X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-050Main Harness/Roof Connection X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-023 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-120 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-001Main Harness/ Engine Connection X-120Modulo Relays R9-R16 + Fuses F37-F40 X-050Main Harness/Roof Connection X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-073 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-092 SP-073 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-392Front Loader Ready Predisposition X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-073 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-093 SP-073 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-380Main Harness/ Front Loader Connection X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-073 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-094 SP-073 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-108 SP-118 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-220XCM CN2 SP-118 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-389Reverse Alarm

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Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100)

Electrical systems - Harnesses and connectors

87314762

MOIL13TR00089AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 13 CONNECTOR X-130 - Fuses Module F1-F32 PIN WIRE NUMBER NUMBER 1A 375 (GN) 1B 466 (BL)

2A 2B

1179 (BL) 187 (BL/WH)

3A 3B

662 (BL) 1143 (OR)

4A 4B

1288 (BL) 1244 (RD)

5A 5B

1286 (BR) 105 (OR/WH)

6A 6B 7A 7B

1197 (BR) 188 (OR/BK) 198 (BR) 201 (YE)

8A 8B 9A 9B 10A 10B 11A 11B 12A 12B

676 (BL) 1158 (RD) 1084 (BR) 11C (BK/YE) 1092 (BR) 189 (GY/BL) 1206 (BR) 417 (WH) 1285 (BR) 912 (BR/GY)

CONNECTOR X-130 - Fuses Module F1-F32 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-096 X-130Fuses module F1-F32 X-130Fuses module F1-F32 X-110Modulo Relays R1-R8 + Fuses F33-F36 SP-074 X-130Fuses module F1-F32 X-130Fuses module F1-F32 X-200XCM CN1-A X-130Fuses module F1-F32 SP-025 X-130Fuses module F1-F32 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-130Fuses module F1-F32 SP-024 X-130Fuses module F1-F32 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-130Fuses module F1-F32 SP-070 X-012Interconnect Transmission / Trailer Socket J-003Trailer Socket ISO SP-070 X-130Fuses module F1-F32 X-130Fuses module F1-F32 SP-103 SP-070 X-130Fuses module F1-F32 X-50140A Socket ISO 1 X-130Fuses module F1-F32 SP-025 X-130Fuses module F1-F32 X-130Fuses module F1-F32 SP-065 SP-070 X-130Fuses module F1-F32 X-130Fuses module F1-F32 SP-068 SP-070 X-130Fuses module F1-F32 X-130Fuses module F1-F32 SP-020 SP-070 X-130Fuses module F1-F32 X-130Fuses module F1-F32 SP-145 X-130Fuses module F1-F32 SP-070 X-130Fuses module F1-F32 SP-119

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Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-130 - Fuses Module F1-F32 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 13A 1125 (BR) 13B 448 (BL)

14A 14B 15A 15B

217 (BR) 1166 (BR) 289 (BL) 1142 (OR/WH)

16A 16B

683 (BR) 1134 (OR/WH)

17A 17B 18A 18B

1118 (BR) 381 (OR) 446 (BL) 372 (BL)

19A 19B 20A 20B 21A 21B 22A 22B 23A 23B

32 (BL) 1105 (OR/WH) 687 (BR) 1100 (OR/BL) 923 (BR/GY) 1189 (BR) 664 (BR) 1297 (WH/BL) 699 (WH) 1162 (YE)

24A 24B 25A 25B 26A

697 703 698 701 679

26B

1088 (BL/YE)

27A 27B

680 (BR) 1196 (OR)

28A 28B 29A 29B 30A 30B

695 (BR) 1159 (OR) 682 (BR) 635 (WH/BL) 444 (BL) 373 (BL)

31A 31B 32A

685 (BL) 171 (BR) 258 (RD)

32B

684 (BL)

(WH) (YE) (WH) (YE/BK) (GY)

SP-025 X-130Fuses module F1-F32 X-130Fuses module F1-F32 X-110Modulo Relays R1-R8 + Fuses F33-F36 SP-070 X-130Fuses module F1-F32 X-130Fuses module F1-F32 SP-018 X-130Fuses module F1-F32 SP-025 X-130Fuses module F1-F32 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-072 X-130Fuses module F1-F32 X-130Fuses module F1-F32 X-050Main Harness/Roof Connection X-130Fuses module F1-F32 SP-070 X-130Fuses module F1-F32 SP-037 X-130Fuses module F1-F32 SP-096 X-130Fuses module F1-F32 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-130Fuses module F1-F32 SP-074 X-130Fuses module F1-F32 SP-030 SP-070 X-130Fuses module F1-F32 X-130Fuses module F1-F32 SP-029 X-130Fuses module F1-F32 SP-113 X-130Fuses module F1-F32 SP-070 X-130Fuses module F1-F32 SP-070 X-130Fuses module F1-F32 SP-066 X-130Fuses module F1-F32 SP-071 X-098Main/ 7 Pole Socket Extension X-130Fuses module F1-F32 X-130Fuses module F1-F32 SP-071 X-130Fuses module F1-F32 SP-012 X-130Fuses module F1-F32 SP-071 X-130Fuses module F1-F32 SP-058 X-510Key SW 15 X-130Fuses module F1-F32 X-319Clutch Pedal SW X-130Fuses module F1-F32 SP-070 X-130Fuses module F1-F32 X-130Fuses module F1-F32 X-001Main Harness/ Engine Connection X-130Fuses module F1-F32 SP-072 SP-067 X-130Fuses module F1-F32 SP-070 X-130Fuses module F1-F32 X-130Fuses module F1-F32 SP-118 SP-096 X-130Fuses module F1-F32 X-130Fuses module F1-F32 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-130Fuses module F1-F32 SP-024 X-130Fuses module F1-F32 SP-017 X-509Key SW 30 X-130Fuses module F1-F32 SP-036 X-130Fuses module F1-F32 47538922 29/05/2013

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Electrical systems - Harnesses and connectors

87314761

MOIL13TR00090AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 14 CONNECTOR X-140 - Module R17-R24 Fuse 41-44 CONNECTOR X-140 - Module R17-R24 Fuse 41-44 PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER R17_30 X-140Module R17-R24 Fuse 41-44 Wire harnesses - Electrical 787 (BR/GY) SP-113 schematic frame 11 (55.100) Wire R17_85 X-140Module R17-R24 Fuse 41-44 harnesses - Electrical schematic 1009 (GN) frame 24 (55.100) X-358Handbrake SW R17_86 775 (BR/GY) SP-113 X-140Module R17-R24 Fuse 41-44 R17_87 X-140Module R17-R24 Fuse 41-44 779 (YE/BL) SP-111 R18_30 924 (BR/GY) SP-113 X-140Module R17-R24 Fuse 41-44 R18_85 X-140Module R17-R24 Fuse 41-44 1195 (BK) SP-023 R18_86 X-140Module R17-R24 Fuse 41-44 927 (BR/WH) X-381Main Harness/ Trailer Brake Connection R18_87 X-140Module R17-R24 Fuse 41-44 922 (YE/BL) SP-111 R21_30 1054 (BK/YE) SP-068 X-140Module R17-R24 Fuse 41-44 R21_85 862 (BK) SP-023 X-140Module R17-R24 Fuse 41-44 R21_86 X-140Module R17-R24 Fuse 41-44 28 (YE/RD) SP-053 R21_87 X-140Module R17-R24 Fuse 41-44 828 (YE/GN) X-188Main Harness/ Transmission OPT Connection

87314762

MOIL13TR00091AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 15 CONNECTOR X-150 - X-150 PIN NUMBER F1_9 F5_1 F5_5 F6_2 F6_6 F7_3 F7_7 F8_4 F8_8 F1_13 F2_10 F2_14 F3_11 F3_15 F4_12 F4_16 R1_30 R1_85 R1_86 R1_87 R2_30 R2_85 R2_86 R2_87 R3_30 R3_85 R3_86

WIRE NUMBER 669 (BL) 452 (GN/GY) 657 (RD) 1296 (YE/GN) 672 (RD) 454 (GN/GY) 2500 (RD) 1072 (TQ/WH) 852 (BL) 660 (TQ/BK) 670 (BL) 661 (TQ/WH) 671 (BL) 1149 (RD/YE) 659 (RD) 1155 (WH/GN) 661 (TQ/WH) 666 (BK) 1131 (WH/YE) 1156 (TQ/WH) 658 (BL) 665 (BK) 1133 (OR/WH) 673 (RD) 1157 (WH/BL) 438 (BK) 439 (OR/WH)

R3_87

440 (BL)

R4_30 R4_85 R4_86 R4_87

660 (TQ/BK) 667 (BK) 1129 (GN/WH) 1128 (TQ/GN)

CONNECTOR X-150 - X-150 CIRCUIT REFERENCE SP-143 X-150 X-150 X-030Fan Speed SW SP-059 X-150 X-150 SP-055 X-150 SP-059 X-150 X-031A/C SW SP-059 X-150 X-150 X-039Radio SP-143 X-150 X-150 X-150 X-150 SP-143 X-150 X-150 X-150 SP-060 X-150 SP-054 SP-059 X-150 X-150 X-039Radio X-150 X-150 X-150 X-403Roof Ground 2 X-065Work lamp Switch X-150 X-150 SP-039 SP-060 X-150 X-150 X-403Roof Ground 2 SP-043 X-150 X-150 SP-059 X-150 SP-043 X-150 X-403Roof Ground 2 X-150 X-050Main Circuit Connection 1 X-150 X-050Main Circuit Connection 1 X-150 X-150 X-403Roof Ground 2 X-150 X-150 SP-044 X-150 SP-040

MOIL12TR00934AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100)

Electrical systems - Harnesses and connectors

MOIL12TR0441AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 16 CONNECTOR X-160 - Main Power Connection CONNECTOR X-160 - Main Power Connection PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER Wire harnesses - Electrical A 1055 (BL) X-160Cab Power/ Main Harness schematic frame 21 (55.100) 668 (BL) Connection SP-036 X-160Main Power Connection SP-060 B 1049 (BL) SP-036 X-160Cab Power/ Main 281 (BL) Harness Connection X-160Main Power Connection SP-143

84136444

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 17 CONNECTOR X-178 - air brake pressure sensor CONNECTOR X-178 - air brake pressure sensor PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 X-178air brake pressure sensor 170 (BK/YE) X-372Air brake 2 X-178air brake pressure sensor 212 (WH) X-372Air brake 3 X-204Tecu X-180 main-isobus 166 (BK) connection

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 18 CONNECTOR X-180 - main-isobus connection CONNECTOR X-180 - main-isobus connection PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER Wire harnesses - Electrical A1 1067 (YE) X-336Diagnostic Socket 2 schematic frame 12 (55.100) Wire 37 (YE) X-180MAIN-ISOBUS Connector harnesses - Electrical schematic X-203SWCD display X-180mainframe 13 (55.100) isobus connection A2 1066 (GN) X-336Diagnostic Socket 2 164 (GN) X-180MAIN-ISOBUS Connector X-203SWCD display X-180mainisobus connection A3 1058 (GN) SP-101L X-180MAIN-ISOBUS 166 (GN) Connector X-204Tecu X-180main-isobus connection A4 1059 (YE) SP-101H X-180MAIN-ISOBUS 167 (YE) Connector X-204Tecu X-180main-isobus connection X-180main-isobus connection A5 1057 (GN) SP-305L 336 (GN) X-180MAIN-ISOBUS Connector SP-306L A6 1062 (YE) SP-305H X-180main-isobus 337 (YE) connection X-180MAIN-ISOBUS Connector SP-306H A7 1032 (BK) X-180MAIN-ISOBUS Connector 1063 (BK) X-660Main Harness/ ISOBUS Connection to External CAB X-180main-isobus connection SP-308 A8 1031 (RD) X-180MAIN-ISOBUS Connector 1064 (RD) X-660Main Harness/ ISOBUS Connection to External CAB X-180main-isobus connection SP-307 B1 878 (WH/RD) SP-167 X-180MAIN-ISOBUS 995 (WH/RD) Connector X-204Tecu X-180main-isobus connection B2 875 (TQ/BK) X-180MAIN-ISOBUS Connector 994 (TQ/BK) SP-050 X-204Tecu X-180main-isobus connection

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Electrical systems - Harnesses and connectors

CONNECTOR X-180 - main-isobus connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER B3 876 (TQ) 993 (TQ)

1070 (GN/WH) 988 (GN/WH)

1006 (RD/GN) 1045 (RD/G)

1003 (RD/BK) 818 (RD/BK)

1023 (BK) 1024 (BK)

1042 (BK) 981 (OR)

1041 (OR/BK) 980 (OR/BK)

C2 C3 C4 C5 C6 C7 C8

X-180MAIN-ISOBUS Connector SP-051 X-204Tecu X-180main-isobus connection X-180MAIN-ISOBUS Connector SP-172 X-204Tecu X-180main-isobus connection X-180main-isobus connection SP-168 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-180MAIN-ISOBUS Connector X-180main-isobus connection SP-169 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-180MAIN-ISOBUS Connector X-280GROUND X-180MAINISOBUS Connector X-180main-isobus connection SP-144 X-204Tecu X-180main-isobus connection X-660Main Harness/ ISOBUS Connection to External CAB X-180MAIN-ISOBUS Connector X-204Tecu X-180main-isobus connection X-660Main Harness/ ISOBUS Connection to External CAB X-180MAIN-ISOBUS Connector -

87699386

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Wire harnesses - Electrical schematic frame 12 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

CONNECTOR X-183 - Creeper Solenoid PIN WIRE NUMBER NUMBER 1 307 (GN) 2

441 (GN/BK)

CONNECTOR X-183 - Creeper Solenoid CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-188Cab/Trans Split Connector X-183Creeper Solenoid X-188Cab/Trans Split Connector X-183Creeper Solenoid

82012083

MOIL13TR00093AA

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-184 - FWD Syncro Solenoid CONNECTOR X-184 - FWD Syncro Solenoid WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 493 (WH) 2

489 (WH/BK)

X-184FWD Syncro Solenoid X-300Cab/Trans Split Connector X-184FWD Syncro Solenoid X-300Cab/Trans Split Connector

82012083

MOIL12TR00168AA

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-185 - REV Syncro Solenoid CONNECTOR X-185 - REV Syncro Solenoid WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 501 (WH/GN) 2

491 (WH/TQ)

X-185REV Syncro Solenoid X-300Cab/Trans Split Connector X-185REV Syncro Solenoid X-300Cab/Trans Split Connector

82012083

MOIL12TR00169AA

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-186 - 1-4 Syncro Solenoid CONNECTOR X-186 - 1-4 Syncro Solenoid WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 503 (WH/OR) 2

545 (WH/RD)

X-1861-4 Syncro Solenoid X-300Cab/Trans Split Connector X-1861-4 Syncro Solenoid X-300Cab/Trans Split Connector

82012083

MOIL12TR00170AA

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-187 - 5-8 Syncro Solenoid CONNECTOR X-187 - 5-8 Syncro Solenoid WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 472 (WH/BL) 2

480 (WH/YE)

X-1875-8 Syncro Solenoid X-300Cab/Trans Split Connector X-1875-8 Syncro Solenoid X-300Cab/Trans Split Connector

82012083

MOIL12TR00171AA

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-188 - Cab/Trans Split Connector CONNECTOR X-188 - Cab/Trans Split Connector WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1200 (BR/YE) 137 (BR/YE)

1085 (BK/WH) 1201 (BK/WH)

1086 (BK/YE) 1087 (BK/YE)

1089 (BK) 286 (BK)

101 (WH/GN) 885 (OR/BK)

102 (BK/WH) 73 (OR/WH)

306 (GN) 307 (GN)

X-210XCM CN1-B X-188Main Harness/ Transmission OPT Connection X-333Radar True Ground Speed Sensor X-188Cab/Trans Split Connector X-333Radar True Ground Speed Sensor X-188Cab/Trans Split Connector X-210XCM CN1-B X-188Main Harness/ Transmission OPT Connection X-333Radar True Ground Speed Sensor X-188Cab/Trans Split Connector X-188Main Harness/ Transmission OPT Connection SP-068 X-333Radar True Ground Speed Sensor X-188Cab/Trans Split Connector X-188Main Harness/ Transmission OPT Connection X-280GROUND X-188Cab/Trans Split Connector X-504Creeper RAIL SW X-188Main Harness/ Transmission OPT Connection X-210XCM CN1-B X-188Cab/Trans Split Connector X-522Creeper NOT-RAIL SW X-210XCM CN1-B X-188Main Harness/ Transmission OPT Connection X-240XCM CN3-B X-188Main Harness/ Transmission OPT Connection X-188Cab/Trans Split Connector X-183Creeper Solenoid

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Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-188 - Cab/Trans Split Connector WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 8 379 (GN/BK) 441 (GN/BK)

104 (WH) 295 (WH)

819 (BL) 838 (BL)

30 (RD) 821 (RD)

828 (YE/GN) 831 (YE/GN)

167 (BK) 29 (BK)

X-220XCM CN2 X-188Main Harness/ Transmission OPT Connection X-188Cab/Trans Split Connector X-183Creeper Solenoid X-188Cab/Trans Split Connector SP-146 X-188Main Harness/ Transmission OPT Connection SP-145 X-188Main Harness/ Transmission OPT Connection SP-202L X-188Cab/Trans Split Connector SP-116 X-188Cab/Trans Split Connector SP-117 X-188Main Harness/ Transmission OPT Connection SP-202H X-140Module R17-R24 Fuse 41-44 X-188Main Harness/ Transmission OPT Connection X-188Cab/Trans Split Connector SP-140 X-204Tecu X-180main-isobus connection SP-175 X-188Cab/Trans Split Connector -

MOIL12TR00230AA

MOIL12TR00172AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-189 - Rear PTO Brake Solenoid CONNECTOR X-189 - Rear PTO Brake Solenoid WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 589 (BR/WH) 2

582 (BK)

X-300Cab/Trans Split Connector X-189Rear PTO Brake Solenoid X-189Rear PTO Brake Solenoid SP-088

82012083

MOIL12TR00173AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 19 CONNECTOR X-190 - PTO Manage SW PIN WIRE NUMBER NUMBER 1 704 (OR/WH) 2 3 4 5 6

655 (GY/BL) 654 (GY/BL) 694 (OR/TQ)

37 (BK)

8 9

1192 (YE/BK) 145 (BK)

143 (YE/BK)

CONNECTOR X-190 - PTO Manage SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-190PTO Manage SW X-351PTO Brake on Speed Lever X-190PTO Manage SW SP-139 SP-139 X-190PTO Manage SW X-190PTO Manage SW X-230XCM CN3-A X-203SWCD display X-180mainisobus connection X-190PTO Manage SW SP-058 X-190PTO Manage SW X-280GROUND SP-058 X-190PTO Manage SW

84819781

MOIL13TR00094AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-192 - Creeper SW PIN NUMBER 1 2 3 4 5 6 7 8 9 10

WIRE NUMBER 799 (GY/BL) 721 (GY/BK) 53 (BK) 465 (YE/BK) -

CONNECTOR X-192 - Creeper SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 04 (55.100) SP-020 X-192Creeper SW X-192Creeper SW X-230XCM CN3-A SP-022 X-192Creeper SW SP-058 X-192Creeper SW -

84819781

MOIL13TR00095AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-194 - 4/5 Syncro Position Sensor CONNECTOR X-194 - 4/5 Syncro Position Sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 724 (TQ/WH) 2

72 (GY)

735 (BK/WH)

SP-005 X-1944/5 Syncro Position Sensor X-300Cab/Trans Split Connector X-1944/5 Syncro Position Sensor SP-007 X-1944/5 Syncro Position Sensor

84062580

MOIL12TR00174AA

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-195 - F/R Syncro Position Sensor CONNECTOR X-195 - F/R Syncro Position Sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 725 (TQ/WH) 2

722 (GY/GN)

736 (BK/WH)

SP-005 X-195F/R Syncro Position Sensor X-300Cab/Trans Split Connector X-195F/R Syncro Position Sensor SP-007 X-195F/R Syncro Position Sensor

84062580

MOIL12TR00175AA

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-196 - Oil Pressure Sensor CONNECTOR X-196 - Oil Pressure Sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER A 737 (BK/WH) B 728 (TQ/WH) C 738 (BL/WH)

SP-007 X-196Oil Pressure Sensor X-196Oil Pressure Sensor SP-005 X-196Oil Pressure Sensor X-300Cab/Trans Split Connector

84078681

MOIL12TR00176AA

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-197 - BDS SW PIN NUMBER 1 2 3 4 5 6 7 8 9 10

WIRE NUMBER 1501 (YE) 38 (BL) 1278 (GY/BL) 1264 (BK) 1052 (YE/BK) 2 (BK) 1 (YE/BK)

CONNECTOR X-197 - BDS SW CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

Wire harnesses - Electrical X-197BDS SW SP-150 schematic frame 01 (55.100) SP-074 X-197BDS SW X-460ADIC CN2 X-197BDS SW X-197BDS SW SP-022 X-197BDS SW SP-058 X-024Roof cable connection X-056B X-892Battery Negative Stud X-893Boost Terminal Negative

84819781

MOIL12TR0443AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-199 - Range L PIN WIRE NUMBER NUMBER A 78 (OR) B

94 (TQ/WH)

CONNECTOR X-199 - Range L CIRCUIT REFERENCE X-300Cab/Trans Split Connector X-199Range L SP-005 X-199Range L

82012093

MOIL12TR00177AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 20 CONNECTOR X-200 - XCM CN1-A PIN NUMBER 1 2 3 4

WIRE NUMBER 708 (OR/BK) 709 (OR/BK) 707 (OR/BK) 46 (RD/GN)

124 (BK/WH)

425 (VT)

435 (GN/WH)

390 (YE/BK)

9 10 11

50 (RD)

130 (GN/WH)

580 (YE/RD)

187 (BL/WH)

15 16 17 18 19 20 21 22 23 24 25 26

1191 (YE) 1190 (GN) 220 (BK) 216 (BK/YE) 1073 (RD) 1074 (BL) 85 (BK/WH) 221 (BK) 222 (BK)

CONNECTOR X-200 - XCM CN1-A CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-200XCM CN1-A SP-103 X-200XCM CN1-A SP-103 X-200XCM CN1-A SP-103 X-200XCM CN1-A X-300Main Harness/ Trasmission Connection X-200XCM CN1-A X-300Main Harness/ Trasmission Connection X-200XCM CN1-A X-300Main Harness/ Trasmission Connection X-200XCM CN1-A X-300Main Harness/ Trasmission Connection X-319Clutch Pedal SW X-200XCM CN1-A X-200XCM CN1-A X-300Main Harness/ Trasmission Connection X-200XCM CN1-A X-300Main Harness/ Trasmission Connection X-200XCM CN1-A X-001Main Harness/ Engine Connection X-130Modulo Fuses F1-F32 X-200XCM CN1-A SP-102H X-200XCM CN1-A SP-102L X-200XCM CN1-A X-200XCM CN1-A X-280GROUND SP-068 X-200XCM CN1-A X-200XCM CN1-A SP-201H X-200XCM CN1-A SP-201L X-200XCM CN1-A SP-009 X-200XCM CN1-A X-280GROUND SP-007 X-013Head-lamp/engine harness connection

82028493

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Electrical systems - Harnesses and connectors

MOIL12TR0446AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-201 - in cab connector PIN WIRE NUMBER NUMBER 1 890 (RD) 2 3 4 5 6 7 8 9

891 (GN) 960 (GN) 914 (YE) 958 (YE) 43 (RD) 1037 (RD/GN) 554 (BK) 1022 (BK)

CONNECTOR X-201 - in cab connector CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-201in cab connector X-206in cab relay X-201in cab connector SP-304L X-201in cab connector SP-305L X-201in cab connector SP-304H X-201in cab connector SP-305H X-201in cab connector SP-307 SP-168 X-201in cab connector X-201in cab connector SP-308 SP-144 X-201in cab connector

MOIL12TR00936AA

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Wire harnesses - Electrical schematic frame 12 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-203 - SWCD display PIN WIRE NUMBER NUMBER 5 915 (YE) 6 917 (GN) 9 37 (YE) 10

164 (GN)

13 14 15

1005 (RD/GN) 1029 (BK) 1002 (RD/BK)

CONNECTOR X-203 - SWCD display CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-203SWCD display SP-301H X-203SWCD display SP-301L X-203SWCD display X-180mainisobus connection X-203SWCD display X-180mainisobus connection X-203SWCD display SP-168 X-203SWCD display SP-144 X-203SWCD display SP-169

82016219

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Wire harnesses - Electrical schematic frame 12 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-204 - Tecu PIN WIRE NUMBER NUMBER 1 937 (YE) 2 939 (GN) 4 167 (YE) 5

166 (GN)

10 11 14

996 (RD/GN) 1026 (BK) 1042 (BK)

1041 (OR/BK)

16 19

999 (RD/BK) 993 (TQ)

21 22

1028 (BK) 994 (TQ/BK)

988 (GN/WH)

995 (WH/RD)

CONNECTOR X-204 - Tecu CIRCUIT REFERENCE X-204Tecu SP-303H X-204Tecu SP-303L X-204Tecu X-180main-isobus connection X-204Tecu X-180main-isobus connection X-204Tecu SP-168 X-204Tecu SP-144 X-204Tecu X-180main-isobus connection X-204Tecu X-180main-isobus connection X-204Tecu SP-169 X-204Tecu X-180main-isobus connection X-204Tecu SP-144 X-204Tecu X-180main-isobus connection X-204Tecu X-180main-isobus connection X-204Tecu X-180main-isobus connection

87410946

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 12 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-206 - in cab relay PIN NUMBER 1 2 3 4 5 6

WIRE NUMBER 1030 (BK) 956 (YE) 920 (YE) 957 (GN) 895 (GN) 890 (RD)

CONNECTOR X-206 - in cab relay CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-206in cab relay SP-144 X-206in cab relay SP-305H X-206in cab relay SP-304H X-206in cab relay SP-305L X-206in cab relay SP-304L X-201in cab connector X-206in cab relay

MOIL12TR00937AA

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Wire harnesses - Electrical schematic frame 12 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-207 - Active bus termination CONNECTOR X-207 - Active bus termination WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER A B C D E

555 (RD) 1012 (RD/BK) 1025 (BK) 561 (BK) 888 (YE)

783 (GN)

X-207Active bus termination SP-307 Wire harnesses - Electrical SP-169 X-207Active bus termination schematic frame 12 (55.100) X-207Active bus termination SP-144 SP-308 X-207Active bus termination X-207Active bus termination SP-303H X-207Active bus termination SP-303L

MOIL12TR00938AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 21 CONNECTOR X-210 - XCM CN1-B PIN WIRE NUMBER NUMBER 1 723 (GY/GN) 2

136 (GY/WH)

3 4

114 (BL/RD) 52 (YE/RD)

109 (GY/BK)

48 (RD)

108 (BL/YE)

8 9

113 (GY/BK) 117 (GY/GN)

133 (YE/GN)

751 (WH/OR)

207 (WH/GN)

386 (YE/GN)

69 (BL/RD)

15 16 17

98 (TQ/WH)

CONNECTOR X-210 - XCM CN1-B CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-210XCM CN1-B X-300Main Harness/ Trasmission Connection X-210XCM CN1-B X-300Main Harness/ Trasmission Connection X-326EDC Mouse X-210XCM CN1-B X-327EDC POT Panel X-210XCM CN1-B X-327EDC POT Panel X-210XCM CN1-B X-327EDC POT Panel X-210XCM CN1-B X-327EDC POT Panel X-210XCM CN1-B X-326EDC Mouse X-210XCM CN1-B X-210XCM CN1-B X-300Main Harness/ Trasmission Connection X-210XCM CN1-B X-300Main Harness/ Trasmission Connection X-300Main Harness/ Trasmission Connection X-210XCM CN1-B X-210XCM CN1-B X-318Shuttle Lever X-210XCM CN1-B X-318Shuttle Lever X-210XCM CN1-B X-300Main Harness/ Trasmission Connection X-210XCM CN1-B SP-006

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Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 18 116 (GN/BK) 19 1200 (BR/YE)

20 21

118 (BR/WH) 885 (OR/BK)

22 23 24

1280 (BL/WH) 1168 (BL/YE) 230 (YE/GN)

122 (GY/BL)

764 (RD/WH)

27 28

73 (OR/WH)

29 30 31 32 33

22B (RD/BL) 26B (RD/WH) 1201 (BK/WH)

CONNECTOR X-210 - XCM CN1-B CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-326EDC Mouse X-210XCM CN1-B X-210XCM CN1-B X-188Main Harness/ Transmission OPT Connection X-326EDC Mouse X-210XCM CN1-B X-188Main Harness/ Transmission OPT Connection X-210XCM CN1-B X-093LH Stop X-210XCM CN1-B X-210XCM CN1-B X-094RH Stop X-210XCM CN1-B X-100Main harness/armerest connection X-210XCM CN1-B X-300Main Harness/ Trasmission Connection X-300Main Harness/ Trasmission Connection X-210XCM CN1-B X-210XCM CN1-B X-188Main Harness/ Transmission OPT Connection X-210XCM CN1-B SP-016 X-210XCM CN1-B SP-010 X-210XCM CN1-B X-188Main Harness/ Transmission OPT Connection -

82028495

MOIL12TR0447AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 22 CONNECTOR X-220 - XCM CN2 PIN WIRE NUMBER NUMBER 1 2 554 (WH/TQ) 3 548 (WH/YE) 4

127 (GN/WH)

131 (GN/YE)

551 (WH/RD)

577 (YE/BK)

8 9 10 11 12

91 (PK) 83 (WH)

379 (GN/BK)

193 (TQ/GN)

15 16 17 18 19 20

1306 (WH/BK) 89 (OR/BL) 185 (TQ/BK)

223 (BK)

22 23 24

90 (PK/BK)

92 (PK/WH)

224 (BK)

CONNECTOR X-220 - XCM CN2 CIRCUIT REFERENCE X-201in cab connector SP-308 X-300Main Harness/ Trasmission Connection X-220XCM CN2 X-220XCM CN2 X-300Main Harness/ Trasmission Connection X-220XCM CN2 X-300Main Harness/ Trasmission Connection X-300Main Harness/ Trasmission Connection X-220XCM CN2 X-220XCM CN2 X-001Main Harness/ Engine Connection SP-007 X-016LH front headlamp X-120Modulo Relays R9-R16 + Fuses F37-F40 X-220XCM CN2 X-220XCM CN2 X-188Main Harness/ Transmission OPT Connection X-220XCM CN2 X-100Main harness/armrest connection X-220XCM CN2 SP-092 SP-007 X-017RH front headlamp X-220XCM CN2 X-100Main harness/armrest connection SP-008 X-013Head-lamp/engine harness connection X-534EDC Led Panel X-220XCM CN2 X-534EDC Led Panel X-220XCM CN2 X-220XCM CN2 X-280GROUND

87694552

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100)

Electrical systems - Harnesses and connectors

MOIL12TR0448AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 23 CONNECTOR X-230 - XCM CN3-A PIN WIRE NUMBER NUMBER 1 773 (TQ) 2 60 (GY) 3 4 5

6 (YE/RD) 146 (PK/WH) 57 (OR)

6 7

115 (TQ) 369 (WH)

119 (OR/WH)

9 10 11 12

149 (BL) 147 (OR/TQ) 694 (OR/TQ)

389 (TQ/WH)

14 15

74 (BL/YE) 382 (WH)

16 17

721 (GY/BK) 211 (GN)

64 (GY/RD)

739 (BL/WH)

321 (BR/BK)

21 22

1111 (OR) 203 (WH)

23 24 25 26

633 (TQ/GN) 1307 (GN/BK) 194 (TQ)

CONNECTOR X-230 - XCM CN3-A CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-3744WD SW X-230XCM CN3-A X-230XCM CN3-A X-300Main Harness/ Trasmission Connection X-056Electric fan SP-062 X-230XCM CN3-A SP-155 X-230XCM CN3-A X-300Main Harness/ Trasmission Connection X-326EDC Mouse X-230XCM CN3-A X-322Clutch Pedal Sensor X-230XCM CN3-A X-351PTO Brake on Speed Lever X-230XCM CN3-A X-230XCM CN3-A SP-153 X-230XCM CN3-A SP-154 X-190PTO Manage SW X-230XCM CN3-A X-230XCM CN3-A X-318Shuttle Lever X-230XCM CN3-A SP-008 X-230XCM CN3-A X-318Shuttle Lever X-192Creeper SW X-230XCM CN3-A X-230XCM CN3-A X-300Main Harness/ Trasmission Connection X-230XCM CN3-A X-300Main Harness/ Trasmission Connection X-300Main Harness/ Trasmission Connection X-230XCM CN3-A X-349Fender PTO SW RH X-230XCM CN3-A X-230XCM CN3-A SP-021 X-348Front PTO SW X-230XCM CN3-A X-230XCM CN3-A X-3744WD SW SP-105 X-230XCM CN3-A X-230XCM CN3-A X-100Main harness/armrest connection

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Electrical systems - Harnesses and connectors

MOIL12TR0449AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 24 CONNECTOR X-240 - XCM CN3-B PIN WIRE NUMBER NUMBER 1 55 (OR/BK) 2

56 (BK/WH)

426 (BK/YE)

450 (GN/BK)

5 6 7

561 (WH) 553 (WH/GN)

591 (BR/WH)

195 (YE)

10 11

555 (WH/BK) 359 (BR/VT)

12 13

549 (WH/BL)

197 (OR/BK)

552 (WH/OR)

306 (GN)

196 (BL/GN)

CONNECTOR X-240 - XCM CN3-B CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-240XCM CN3-B X-300Main Harness/ Trasmission Connection SP-308 X-207Active bus termination X-300Main Harness/ Trasmission Connection X-240XCM CN3-B X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-207Active bus termination SP-307 X-350Rear PTO SW X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-240XCM CN3-B X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-300Main Harness/ Trasmission Connection X-240XCM CN3-B X-240XCM CN3-B X-188Main Harness/ Transmission OPT Connection X-240XCM CN3-B X-300Main Harness/ Trasmission Connection

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Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100)

Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 18 209 (BR/GN) 19

200 (BR/WH)

58 (OR/BL)

21 22 23

363 (GY)

24 25 26

740 (GY/BL) 383 (WH/BL)

27 28 29

1305 (TQ/BK) 1302 (BK/YE) 262 (WH)

261 (RD/GN)

254 (RD/YE)

219 (WH)

190 (GY/BL)

218 (GY/BL)

87410946

MOIL12TR0450AA

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Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 25 CONNECTOR X-250 - Home-Enter SW PIN WIRE NUMBER NUMBER 1 240 (PK/BK) 2 3

43 (BK) 241 (WH/BK)

4 5 6 7

76 (BK)

8 9

139 (YE) 40 (BK)

126 (YE)

CONNECTOR X-250 - Home-Enter SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical X-250Home-Enter SW X-450ADIC schematic frame 16 (55.100) CN1 X-201in cab connector SP-307 X-250Home-Enter SW X-450ADIC CN1 X-250Home-Enter SW X-410Steering Column Ground X-250Home-Enter SW SP-012 X-250Home-Enter SW X-410Steering Column Ground X-250Home-Enter SW SP-012

84819781

MOIL12TR0451AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 26 CONNECTOR X-260 - UP-Down SW PIN WIRE NUMBER NUMBER 1 242 (BR/BK) 2 66 (BK) 3 4 5 6 7

243 (BL/BK) 82 (BK)

8 9

245 (YE) 63 (BK)

244 (YE)

CONNECTOR X-260 - UP-Down SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-260UP-Down SW X-450ADIC CN1 Wire harnesses - Electrical X-260UP-Down SW X-410Steering schematic frame 16 (55.100) Column Ground X-260UP-Down SW X-450ADIC CN1 X-260UP-Down SW X-410Steering Column Ground X-260UP-Down SW SP-012 X-260UP-Down SW X-410Steering Column Ground X-260UP-Down SW SP-012

84819781

MOIL12TR0452AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 28 CONNECTOR X-280 - GROUND PIN WIRE NUMBER NUMBER 1 220 (BK) 2 221 (BK) 3 222 (BK) 4

223 (BK)

5 6

224 (BK) 145 (BK)

1260 (BK)

8 9 10

26 (BK) 20 (BK) 36 (BK)

39 (BK)

1266 (BK)

286 (BK)

37 (BK)

167 (BK)

1023 (BK)

CONNECTOR X-280 - GROUND CIRCUIT REFERENCE X-200XCM CN1-A X-280GROUND X-200XCM CN1-A X-280GROUND SP-007 X-013Head-lamp/engine harness connection SP-008 X-013Head-lamp/engine harness connection X-220XCM CN2 X-280GROUND X-190PTO Manage SW X-280GROUND X-300Main Harness/ Trasmission Connection X-280GROUND X-369CRPM +/- SW X-280GROUND X-369CRPM +/- SW X-280GROUND X-303CRPM 1/2 &amp; ON/OFF SW X-280GROUND X-303CRPM 1/2 &amp; ON/OFF SW X-280GROUND X-280GROUND X-0873rd Distributor Solenoid Disposition X-188Main Harness/ Transmission OPT Connection X-280GROUND X-203SWCD display X-180mainisobus connection X-204Tecu X-180main-isobus connection X-280GROUND X-180MAINISOBUS Connector

84153309

MOIL12TR0454AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 12 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 29 CONNECTOR X-295 - Diode PIN WIRE NUMBER NUMBER 1 903 (R/G) 2

908 (G)

CONNECTOR X-295 - Diode CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

Wire harnesses - Electrical X-392Front loader ready predisposition JUMPER X-295Diode schematic frame 23 (55.100) X-295Diode SA1

84121648

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 30 CONNECTOR X-300 - Cab/Trans Split Connector CONNECTOR X-300 - Cab/Trans Split Connector PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 47 (OR/BK) X-340Clutch 3 X-300Cab/Trans Split Wire harnesses - Electrical schematic frame 03 (55.100) Wire 55 (OR/BK) Connector harnesses - Electrical schematic X-240XCM CN3-B X-300Main frame 04 (55.100) Wire harnesses Harness/ Trasmission Connection 2 51 (BK/WH) X-365Clutch 4 X-300Cab/Trans Split - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical 56 (BK/WH) Connector schematic frame 15 (55.100) Wire X-240XCM CN3-B X-300Main harnesses - Electrical schematic Harness/ Trasmission Connection frame 17 (55.100) 3 501 (WH/GN) X-185REV Syncro Solenoid 553 (WH/GN) X-300Cab/Trans Split Connector X-300Main Harness/ Trasmission Connection X-240XCM CN3-B 4 100 (TQ/WH) X-300Main Harness/ Trasmission 1082 (TQ/WH) Connection SP-006 SP-005 X-300Cab/Trans Split Connector 5 45 (RD/GN) X-340Clutch 3 X-300Cab/Trans Split 46 (RD/GN) Connector X-200XCM CN1-A X-300Main Harness/ Trasmission Connection 6 49 (RD) X-365Clutch 4 X-300Cab/Trans Split 50 (RD) Connector X-200XCM CN1-A X-300Main Harness/ Trasmission Connection 7 425 (VT) X-200XCM CN1-A X-300Main 456 (VT) Harness/ Trasmission Connection SP-008 X-015Corner light RH. 8 426 (BK/YE) X-240XCM CN3-B X-300Main 461 (BK/YE) Harness/ Trasmission Connection SP-008 X-014LH corner light 9 435 (GN/WH) X-200XCM CN1-A X-300Main 481 (GN/WH) Harness/ Trasmission Connection X-807Clutch 2 X-300Cab/Trans Split Connector

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Electrical systems - Harnesses and connectors

CONNECTOR X-300 - Cab/Trans Split Connector WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 10 450 (GN/BK) 479 (GN/BK)

1199 (BK/WH) 61 (BK/WH)

58 (OR/BL) 59 (OR/BL)

60 (GY) 72 (GY)

301 (WH) 54 (WH)

491 (WH/TQ) 554 (WH/TQ)

741 (WH/OR) 751 (WH/OR)

57 (OR) 78 (OR)

489 (WH/BK) 555 (WH/BK)

X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-807Clutch 2 X-300Cab/Trans Split Connector SP-007 X-300Cab/Trans Split Connector SP-009 X-300Main Harness/ Trasmission Connection X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-309Drive Speed Sensor (Wheel Speed Sensor) X-300Cab/Trans Split Connector X-230XCM CN3-A X-300Main Harness/ Trasmission Connection X-300Cab/Trans Split Connector X-1944/5 Syncro Position Sensor X-300Main Harness/ Trasmission Connection SP-145 X-300Cab/Trans Split Connector X-309Drive Speed Sensor (Wheel Speed Sensor) X-185REV Syncro Solenoid X-300Cab/Trans Split Connector X-201in cab connector SP-308 X-315Park Brake SW X-300Cab/Trans Split Connector X-300Main Harness/ Trasmission Connection X-210XCM CN1-B X-230XCM CN3-A X-300Main Harness/ Trasmission Connection X-300Cab/Trans Split Connector X-199Range L X-184FWD Syncro Solenoid X-300Cab/Trans Split Connector X-207Active bus termination SP-307

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Electrical systems - Harnesses and connectors

CONNECTOR X-300 - Cab/Trans Split Connector WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 19 493 (WH) 561 (WH) 20

68 (BL/RD) 69 (BL/RD)

21 22

179 (BR/GN) 209 (BR/GN)

124 (BK/WH) 125 (BK/WH)

264 (BR) 303 (BR)

761 (RD/WH) 764 (RD/WH)

176 (OR/BK) 197 (OR/BK)

X-184FWD Syncro Solenoid X-300Cab/Trans Split Connector SP-308 X-207Active bus termination X-316Trans Oil Temp Sensor X-300Cab/Trans Split Connector X-210XCM CN1-B X-300Main Harness/ Trasmission Connection X-300Cab/Trans Split Connector X-344Rear PTO Solenoid X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-200XCM CN1-A X-300Main Harness/ Trasmission Connection X-334EDC RAISE Solenoid X-300Cab/Trans Split Connector X-354Fuel Level X-300Cab/Trans Split Connector X-450ADIC CN1 X-300Main Harness/ Trasmission Connection X-368Diff Lock Clutch SW X-300Cab/Trans Split Connector X-300Main Harness/ Trasmission Connection X-210XCM CN1-B X-344Rear PTO Solenoid X-300Cab/Trans Split Connector X-240XCM CN3-B X-300Main Harness/ Trasmission Connection -

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Electrical systems - Harnesses and connectors

CONNECTOR X-300 - Cab/Trans Split Connector WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 28 117 (GY/GN) 121 (GY/GN)

503 (WH/OR) 552 (WH/OR)

545 (WH/RD) 551 (WH/RD)

472 (WH/BL) 549 (WH/BL)

32 33

127 (GN/WH) 128 (GN/WH)

131 (GN/YE) 132 (GN/YE)

1095 (GY/BL) 757 (GY/BL)

133 (YE/GN) 134 (YE/GN)

X-210XCM CN1-B X-300Main Harness/ Trasmission Connection X-332Right Draft Sensor X-300Cab/Trans Split Connector X-1861-4 Syncro Solenoid X-300Cab/Trans Split Connector X-300Main Harness/ Trasmission Connection X-240XCM CN3-B X-1861-4 Syncro Solenoid X-300Cab/Trans Split Connector X-300Main Harness/ Trasmission Connection X-220XCM CN2 X-1875-8 Syncro Solenoid X-300Cab/Trans Split Connector X-300Main Harness/ Trasmission Connection X-240XCM CN3-B X-220XCM CN2 X-300Main Harness/ Trasmission Connection X-334EDC RAISE Solenoid X-300Cab/Trans Split Connector X-220XCM CN2 X-300Main Harness/ Trasmission Connection X-335EDC LOWER Solenoid X-300Cab/Trans Split Connector SP-020 X-300Main Harness/ Trasmission Connection X-300Cab/Trans Split Connector SP-104 X-210XCM CN1-B X-300Main Harness/ Trasmission Connection X-331Left Draft Sensor X-300Cab/Trans Split Connector

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Electrical systems - Harnesses and connectors

CONNECTOR X-300 - Cab/Trans Split Connector WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 37 122 (GY/BL) 123 (GY/BL)

589 (BR/WH) 591 (BR/WH)

722 (GY/GN) 723 (GY/GN)

64 (GY/RD) 79 (GY/RD)

191 (YE) 195 (YE)

192 (BL/GN) 196 (BL/GN)

210 (GN) 211 (GN)

738 (BL/WH) 739 (BL/WH)

135 (GY/WH) 136 (GY/WH)

199 (BR/WH) 200 (BR/WH)

129 (GN/WH) 130 (GN/WH)

266 (BK) 268 (BK)

480 (WH/YE) 548 (WH/YE)

10 (BK) 1260 (BK)

X-210XCM CN1-B X-300Main Harness/ Trasmission Connection X-300Cab/Trans Split Connector SP-124 X-300Cab/Trans Split Connector X-189Rear PTO Brake Solenoid X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-300Cab/Trans Split Connector X-195F/R Syncro Position Sensor X-210XCM CN1-B X-300Main Harness/ Trasmission Connection X-230XCM CN3-A X-300Main Harness/ Trasmission Connection X-300Cab/Trans Split Connector X-308Range M X-300Cab/Trans Split Connector X-343Diff Lock Solenoid X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-300Cab/Trans Split Connector X-3422WD Solenoid X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-352Ground Rear PTO Speed SW X-300Cab/Trans Split Connector X-230XCM CN3-A X-300Main Harness/ Trasmission Connection X-196Oil Pressure Sensor X-300Cab/Trans Split Connector X-300Main Harness/ Trasmission Connection X-230XCM CN3-A X-328Rock Shaft Position Sensor X-300Cab/Trans Split Connector X-210XCM CN1-B X-300Main Harness/ Trasmission Connection X-341PTO Speed Sensor X-300Cab/Trans Split Connector X-240XCM CN3-B X-300Main Harness/ Trasmission Connection X-335EDC LOWER Solenoid X-300Cab/Trans Split Connector X-200XCM CN1-A X-300Main Harness/ Trasmission Connection SP-028 X-300Main Harness/ Trasmission Connection X-354Fuel Level X-300Cab/Trans Split Connector X-1875-8 Syncro Solenoid X-300Cab/Trans Split Connector X-300Main Harness/ Trasmission Connection X-220XCM CN2 SP-088 X-300Cab/Trans Split Connector X-300Main Harness/ Trasmission Connection X-280GROUND

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Electrical systems - Harnesses and connectors

87708538

MOIL12TR0456AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-303 - CRPM 1/2 &amp; ON/OFF SW CONNECTOR X-303 - CRPM 1/2 & ON/OFF SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 93 (OR/TQ) 2 204 (OR) 3

96 (OR/BK)

4 5 6 7

39 (BK)

80 (YE)

36 (BK)

111 (YE)

Wire harnesses - Electrical SP-011 X-016LH front headlamp schematic frame 16 (55.100) SP-090 X-303CRPM 1/2 &amp; ON/OFF SW X-460ADIC CN2 X-303CRPM 1/2 &amp; ON/OFF SW X-303CRPM 1/2 &amp; ON/OFF SW X-280GROUND X-303CRPM 1/2 &amp; ON/OFF SW SP-012 X-303CRPM 1/2 &amp; ON/OFF SW X-280GROUND X-303CRPM 1/2 &amp; ON/OFF SW SP-012

84819781

MOIL12TR00178AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-304 - STARTER MOTOR PIN WIRE NUMBER NUMBER 1 822 (R)

CONNECTOR X-304 - STARTER MOTOR CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-304STARTER MOTOR X-013Alternator

84138841

MOIL13TR00058AA

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-306 - RH Rear Work Lamp 2 CONNECTOR X-306 - RH Rear Work Lamp 2 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 140 (TQ/WH) 2 141 (BK)

X-306RH Rear Work Lamp 2 SP-039 Wire harnesses - Electrical schematic frame 06 (55.100) X-306RH Rear Work Lamp 2 X-403Roof Ground 2

82012083

MOIL13TR00096AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-307 - LH Rear Work Lamp 2 CONNECTOR X-307 - LH Rear Work Lamp 2 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 62 (TQ/WH) 2 153 (BK)

X-307LH Rear Work Lamp 2 SP-039 Wire harnesses - Electrical schematic frame 06 (55.100) X-307LH Rear Work Lamp 2 X-403Roof Ground 2

82012083

MOIL12TR0460AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-308 - Range M PIN WIRE NUMBER NUMBER A 79 (GY/RD) B

95 (TQ/WH)

CONNECTOR X-308 - Range M CIRCUIT REFERENCE X-300Cab/Trans Split Connector X-308Range M SP-010 X-017RH front headlamp

MOIL12TR00231AA

MOIL12TR00179AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-309 - Drive Speed Sensor (Wheel Speed Sensor) CONNECTOR X-309 - Drive Speed Sensor (Wheel Speed Sensor) WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 59 (OR/BL)

54 (WH)

Wire harnesses - Electrical X-309Drive Speed Sensor (Wheel Speed Sensor) X-300Cab/Trans Split schematic frame 14 (55.100) Connector X-300Cab/Trans Split Connector X-309Drive Speed Sensor (Wheel Speed Sensor)

82012083

MOIL12TR0462AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 31 CONNECTOR X-313 - Reactivity SW PIN WIRE NUMBER NUMBER 1 190 (GY/BL) 2 3 4 5 6 7 8 9 10

227 (GY/BL) 1194 (BK) 1283 (YE/BK) 248 (BK) 238 (YE)

CONNECTOR X-313 - Reactivity SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-313Reactivity SW X-240XCM CN3-B X-313Reactivity SW SP-020 X-313Reactivity SW SP-022 X-313Reactivity SW SP-058 SP-022 X-313Reactivity SW X-313Reactivity SW SP-058

84819781

MOIL12TR00180AA

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Wire harnesses - Electrical schematic frame 15 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-315 - Park Brake SW PIN WIRE NUMBER NUMBER 1 741 (WH/OR) 2

86 (TQ/WH)

CONNECTOR X-315 - Park Brake SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-315Park Brake SW X-300Cab/Trans Split Connector SP-005 X-315Park Brake SW

82012083

MOIL12TR00181AA

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-316 - Trans Oil Temp Sensor CONNECTOR X-316 - Trans Oil Temp Sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER A 1081 (BK/WH) B 68 (BL/RD)

X-316Trans Oil Temp Sensor SP-007 Wire harnesses - Electrical schematic frame 14 (55.100) X-316Trans Oil Temp Sensor X-300Cab/Trans Split Connector

82012093

MOIL12TR00182AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-317 - Front Loader 1 SW CONNECTOR X-317 - Front Loader 1 SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 588 (BK) 2 607 (BK/YE)

X-317Front Loader 1 SW SP-022 X-317Front Loader 1 SW SP-094

82012083

MOIL12TR00183AA

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Wire harnesses - Electrical schematic frame 23 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-318 - Shuttle Lever PIN WIRE NUMBER NUMBER 1 1114 (TQ/WH) 2 207 (WH/GN) 3

386 (YE/GN)

383 (WH/BL)

5 6

628 (OR/WH) 382 (WH)

376 (WH/BL)

8 9 10 11

65 (BK/WH) 389 (TQ/WH)

70 (GY)

71 (BL/YE)

CONNECTOR X-318 - Shuttle Lever CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical SP-006 X-318Shuttle Lever schematic frame 15 (55.100) X-210XCM CN1-B X-318Shuttle Lever X-210XCM CN1-B X-318Shuttle Lever X-240XCM CN3-B X-318Shuttle Lever X-318Shuttle Lever SP-099 X-230XCM CN3-A X-318Shuttle Lever X-319Clutch Pedal SW X-318Shuttle Lever X-318Shuttle Lever SP-009 X-230XCM CN3-A X-318Shuttle Lever X-319Clutch Pedal SW X-318Shuttle Lever X-318Shuttle Lever SP-008

82862752

MOIL12TR0465AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-319 - Clutch Pedal SW PIN WIRE NUMBER NUMBER 1 1088 (BL/YE) 2

390 (YE/BK)

376 (WH/BL)

70 (GY)

CONNECTOR X-319 - Clutch Pedal SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-319Clutch Pedal SW X-130Modulo Wire harnesses - Electrical schematic frame 15 (55.100) Fuses F1-F32 X-319Clutch Pedal SW X-200XCM CN1-A X-319Clutch Pedal SW X-318Shuttle Lever X-319Clutch Pedal SW X-318Shuttle Lever

87687242

MOIL12TR0466AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 32 CONNECTOR X-320 - Gear Lever PIN NUMBER 1 2 3 4

WIRE NUMBER 810 772 156 815

(OR/TQ) (BL) (OR/WH) (PK/WH)

CONNECTOR X-320 - Gear Lever CIRCUIT REFERENCE X-320Gear Lever SP-154 X-320Gear Lever SP-153 SP-099 X-320Gear Lever X-320Gear Lever SP-155

84149200

MOIL12TR00184AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 15 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-321 - Foot Pedal Sensor SW CONNECTOR X-321 - Foot Pedal Sensor SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 2 34 (WH/BK) 3 4

184 (OR) 11 (TQ)

5 6

225 (WH)

7 8

88 (BK) 75 (BK)

Wire harnesses - Electrical schematic frame 16 (55.100) X-321Foot Pedal Sensor SW X-450ADIC CN1 SP-090 X-321Foot Pedal Sensor SW X-460ADIC CN2 X-321Foot Pedal Sensor SW X-013Head-lamp/engine harness connection H-004AHorn X-321Foot Pedal Sensor SW SP-028 X-321Foot Pedal Sensor SW SP-028

87702265

MOIL12TR0467AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-322 - Clutch Pedal Sensor CONNECTOR X-322 - Clutch Pedal Sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 20C (BK/WH) 2 369 (WH) 3

1121 (TQ/WH)

X-322Clutch Pedal Sensor SP-009 X-322Clutch Pedal Sensor X-230XCM CN3-A SP-006 X-322Clutch Pedal Sensor

84062580

MOIL12TR0468AA

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Wire harnesses - Electrical schematic frame 15 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-323 - Front Loader 2 SW PIN NUMBER 1 2 3 4

CONNECTOR X-323 - Front Loader 2 SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 587 627 605 578

(BK) (WH/BK) (TQ/BK) (BK)

SP-022 X-323Front Loader 2 SW X-323Front Loader 2 SW SP-092 X-323Front Loader 2 SW SP-093 SP-022 X-323Front Loader 2 SW

87715977

MOIL12TR00185AA

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Wire harnesses - Electrical schematic frame 23 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-324 - Hand Throttle PIN WIRE NUMBER NUMBER 2 226 (RD) 3 231 (BK/WH) 4 228 (TQ)

CONNECTOR X-324 - Hand Throttle CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-324Hand Throttle X-450ADIC CN1 Wire harnesses - Electrical X-324Hand Throttle X-450ADIC CN1 schematic frame 16 (55.100) X-324Hand Throttle X-460ADIC CN2

87694694

MOIL12TR00186AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-326 - EDC Mouse PIN NUMBER A B C D E F G H

WIRE NUMBER 114 (BL/RD) 113 (GY/BK) 159 (TQ/WH) 120 (BK/WH) 118 (BR/WH) 11A (BK/YE) 116 (GN/BK) 115 (TQ)

CONNECTOR X-326 - EDC Mouse CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-326EDC Mouse X-210XCM CN1-B Wire harnesses - Electrical X-326EDC Mouse X-210XCM CN1-B schematic frame 03 (55.100) X-326EDC Mouse SP-006 SP-009 X-326EDC Mouse X-326EDC Mouse X-210XCM CN1-B SP-068 X-326EDC Mouse X-326EDC Mouse X-210XCM CN1-B X-326EDC Mouse X-230XCM CN3-A

87691061

MOIL12TR00187AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-327 - EDC POT Panel PIN WIRE NUMBER NUMBER 3 109 (GY/BK) 4

52 (YE/RD)

5 6 7

158 (TQ/WH) 160 (BK/WH) 108 (BL/YE)

48 (RD)

CONNECTOR X-327 - EDC POT Panel CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-327EDC POT Panel X-210XCM CN1-B X-327EDC POT Panel X-210XCM CN1-B X-327EDC POT Panel SP-006 SP-009 X-327EDC POT Panel X-327EDC POT Panel X-210XCM CN1-B X-327EDC POT Panel X-210XCM CN1-B

87680680

MOIL12TR00188AA

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Wire harnesses - Electrical schematic frame 03 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-328 - Rock Shaft Position Sensor CONNECTOR X-328 - Rock Shaft Position Sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 144 (BK/WH) 2

135 (GY/WH)

1205 (TQ/WH)

X-328Rock Shaft Position Sensor SP-007 X-328Rock Shaft Position Sensor X-300Cab/Trans Split Connector SP-005 X-328Rock Shaft Position Sensor

84062580

MOIL12TR00189AA

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Wire harnesses - Electrical schematic frame 03 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-329 - Fender SW EDC LH CONNECTOR X-329 - Fender SW EDC LH WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 22A (RD/BL) 2 11B (BK/YE) 3 110 (RD/WH)

X-329Fender SW EDC LH SP-016 SP-068 X-329Fender SW EDC LH X-329Fender SW EDC LH SP-010

84062580

MOIL13TR00097AA

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Wire harnesses - Electrical schematic frame 03 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 33 CONNECTOR X-330 - Fender SW EDC RH PIN WIRE NUMBER NUMBER 1 112 (RD/BL) 2 11D (BK/YE) 3 26A (RD/WH)

CONNECTOR X-330 - Fender SW EDC RH CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-330Fender SW EDC RH SP-016 X-330Fender SW EDC RH SP-068 X-330Fender SW EDC RH SP-010

84062580

MOIL13TR00098AA

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Wire harnesses - Electrical schematic frame 03 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-331 - Left Draft Sensor PIN WIRE NUMBER NUMBER 1 163 (BK/WH) 2 134 (YE/GN) 3

161 (GY/BL)

CONNECTOR X-331 - Left Draft Sensor CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-331Left Draft Sensor SP-007 X-331Left Draft Sensor X-300Cab/Trans Split Connector X-331Left Draft Sensor SP-124

87709663

MOIL12TR00190AA

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Wire harnesses - Electrical schematic frame 03 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-332 - Right Draft Sensor CONNECTOR X-332 - Right Draft Sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 215 (BK/WH) 2 121 (GY/GN) 3

1083 (GY/BL)

SP-007 X-332Right Draft Sensor X-332Right Draft Sensor X-300Cab/Trans Split Connector X-332Right Draft Sensor SP-124

87709663

MOIL12TR00191AA

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Wire harnesses - Electrical schematic frame 03 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-333 - Radar True Ground Speed Sensor CONNECTOR X-333 - Radar True Ground Speed Sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1085 (BK/WH)

1089 (BK)

1086 (BK/YE)

137 (BR/YE)

X-333Radar True Ground Speed Sensor X-188Cab/Trans Split Connector X-333Radar True Ground Speed Sensor X-188Cab/Trans Split Connector X-333Radar True Ground Speed Sensor X-188Cab/Trans Split Connector X-333Radar True Ground Speed Sensor X-188Cab/Trans Split Connector

87712738

MOIL12TR00192AA

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Wire harnesses - Electrical schematic frame 03 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-334 - EDC RAISE Solenoid CONNECTOR X-334 - EDC RAISE Solenoid WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 125 (BK/WH) 2

128 (GN/WH)

X-334EDC RAISE Solenoid X-300Cab/Trans Split Connector X-334EDC RAISE Solenoid X-300Cab/Trans Split Connector

MOIL12TR00232AA

MOIL12TR00193AA

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Wire harnesses - Electrical schematic frame 03 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-335 - EDC LOWER Solenoid CONNECTOR X-335 - EDC LOWER Solenoid WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 129 (GN/WH) 2

132 (GN/YE)

X-335EDC LOWER Solenoid X-300Cab/Trans Split Connector X-335EDC LOWER Solenoid X-300Cab/Trans Split Connector

MOIL12TR00232AA

MOIL12TR00194AA

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Wire harnesses - Electrical schematic frame 03 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-336 - Diagnostic Socket 2 CONNECTOR X-336 - Diagnostic Socket 2 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER A B C D E F

496 (BK) 800 (OR/WH) 805 (RD) 820 (BL) 1067 (YE)

1066 (GN)

H J

SP-022 X-336Diagnostic Socket 2 SP-030 X-336Diagnostic Socket 2 X-336Diagnostic Socket 2 SP-201H X-336Diagnostic Socket 2 SP-201L X-336Diagnostic Socket 2 X-180MAIN-ISOBUS Connector X-336Diagnostic Socket 2 X-180MAIN-ISOBUS Connector -

87516075

MOIL12TR00195AA

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Wire harnesses - Electrical schematic frame 11 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-337 - Hydraulic Master SW PIN NUMBER 1 2 3 4 5 6 7 8 9 10

CONNECTOR X-337 - Hydraulic Master SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 786 781 770 107 -

(YE/RD) (BK/YE)

(BK) (YE/BK)

X-337Hydraulic Master SW SP-053 SP-068 X-337Hydraulic Master SW X-337Hydraulic Master SW SP-022 X-337Hydraulic Master SW SP-058 -

84819781

MOIL13TR00099AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 34 CONNECTOR X-340 - Clutch 3 PIN WIRE NUMBER NUMBER 1 45 (RD/GN) 2

47 (OR/BK)

CONNECTOR X-340 - Clutch 3 CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

X-340Clutch 3 X-300Cab/Trans Split Wire harnesses - Electrical schematic frame 14 (55.100) Connector X-340Clutch 3 X-300Cab/Trans Split Connector

82012083

MOIL12TR00196AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-341 - PTO Speed Sensor CONNECTOR X-341 - PTO Speed Sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 182 (GY/BL) 2 199 (BR/WH) 3

1198 (BK/WH)

X-341PTO Speed Sensor SP-104 X-341PTO Speed Sensor X-300Cab/Trans Split Connector X-341PTO Speed Sensor SP-007

84806091

MOIL13TR00100AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-342 - 2WD Solenoid PIN WIRE NUMBER NUMBER 1 192 (BL/GN) 2

1090 (BK)

CONNECTOR X-342 - 2WD Solenoid CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-300Cab/Trans Split Connector X-3422WD Solenoid X-3422WD Solenoid SP-088

82012083

MOIL12TR00197AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-343 - Diff Lock Solenoid CONNECTOR X-343 - Diff Lock Solenoid WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 191 (YE) 2

1091 (BK)

X-300Cab/Trans Split Connector X-343Diff Lock Solenoid X-343Diff Lock Solenoid SP-088

82012083

MOIL12TR00198AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-344 - Rear PTO Solenoid CONNECTOR X-344 - Rear PTO Solenoid WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 176 (OR/BK) 2

179 (BR/GN)

X-344Rear PTO Solenoid X-300Cab/Trans Split Connector X-300Cab/Trans Split Connector X-344Rear PTO Solenoid

87691973

MOIL12TR00199AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-346 - Front PTO PIN WIRE NUMBER NUMBER 1 1001 (YE/BK) 2 1000 (YE/RD)

CONNECTOR X-346 - Front PTO CIRCUIT REFERENCE X-346AFront PTO X-346Front PTO X-346AFront PTO X-346Front PTO

87691973

MOIL13TR00101AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-346A - Front PTO PIN WIRE NUMBER NUMBER 1 1001 (YE/BK) 2 1000 (YE/RD)

CONNECTOR X-346A - Front PTO CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-346AFront PTO X-346Front PTO X-346AFront PTO X-346Front PTO

87691973

MOIL13TR00102AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-347 - Fender PTO SW LH CONNECTOR X-347 - Fender PTO SW LH WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1120 (GY/BL) 2 1122 (RD/GN) 3

1123 (OR)

X-347Fender PTO SW LH SP-020 X-347Fender PTO SW LH X-349Fender PTO SW RH X-347Fender PTO SW LH SP-021

87691928

MOIL13TR00103AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-348 - Front PTO SW PIN WIRE NUMBER NUMBER 1 1117 (GY/BL) 2 219 (WH) 3

203 (WH)

CONNECTOR X-348 - Front PTO SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-020 X-348Front PTO SW X-348Front PTO SW X-240XCM CN3-B X-348Front PTO SW X-230XCM CN3-A

84062580

MOIL13TR00104AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-349 - Fender PTO SW RH CONNECTOR X-349 - Fender PTO SW RH WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1122 (RD/GN) 2

321 (BR/BK)

1010 (OR)

Wire harnesses - Electrical X-347Fender PTO SW LH schematic frame 04 (55.100) X-349Fender PTO SW RH X-349Fender PTO SW RH X-230XCM CN3-A X-349Fender PTO SW RH SP-021

87691928

MOIL13TR00105AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 35 CONNECTOR X-350 - Rear PTO SW PIN WIRE NUMBER NUMBER 1 1119 (GY/BL) 2 359 (BR/VT) 3

363 (GY)

CONNECTOR X-350 - Rear PTO SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-350Rear PTO SW SP-020 X-350Rear PTO SW X-240XCM CN3-B X-350Rear PTO SW X-240XCM CN3-B

87691928

MOIL12TR0476AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-351 - PTO Brake on Speed Lever CONNECTOR X-351 - PTO Brake on Speed Lever WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 2 704 (OR/WH) 4

119 (OR/WH)

X-190PTO Manage SW X-351PTO Brake on Speed Lever X-351PTO Brake on Speed Lever X-230XCM CN3-A

MOIL12TR00233AA

MOIL12TR00200AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-352 - Ground Rear PTO Speed SW CONNECTOR X-352 - Ground Rear PTO Speed SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1295 (TQ/WH) 2

210 (GN)

SP-005 X-352Ground Rear PTO Speed SW X-352Ground Rear PTO Speed SW X-300Cab/Trans Split Connector

84152155

MOIL12TR0477AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-354 - Fuel Level PIN WIRE NUMBER NUMBER 1 268 (BK) 2

264 (BR)

CONNECTOR X-354 - Fuel Level CIRCUIT REFERENCE X-354Fuel Level X-300Cab/Trans Split Connector X-354Fuel Level X-300Cab/Trans Split Connector

82012083

MOIL12TR00201AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 17 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-355 - Seat SW PIN WIRE NUMBER NUMBER 1 267 (BK) 2 263 (GN)

CONNECTOR X-355 - Seat SW CIRCUIT REFERENCE SP-028 X-355Seat SW X-450ADIC CN1 X-355Seat SW

82012083

MOIL12TR0480AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 17 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-356 - Brakes Not Latched SW CONNECTOR X-356 - Brakes Not Latched SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 298 (OR/BL) 2

270 (GY)

SP-029 X-356Brakes Not Latched SW X-356Brakes Not Latched SW X-450ADIC CN1

87695582

MOIL13TR00106AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-357 - Engine Intake Air Filter CONNECTOR X-357 - Engine Intake Air Filter WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 272 (YE) 2

1103 (BK)

X-357Engine Intake Air Filter X-001Engine - Cab connection X-357Engine Intake Air Filter SP-004

84607243

MOIL12TR0481AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-358 - Handbrake SW PIN WIRE NUMBER NUMBER 1 1187 (BK) 2 1188 (RD) 3 4 5

1106 (OR/WH) 1009 (GN)

CONNECTOR X-358 - Handbrake SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-358Handbrake SW SP-022 X-358Handbrake SW X-460ADIC CN2 SP-030 X-358Handbrake SW X-140Module R17-R24 Fuse 41-44 X-358Handbrake SW

82867472

MOIL12TR0482AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-359 - Trailer brake LAMP switch CONNECTOR X-359 - Trailer brake LAMP switch WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 879 (B)

X-359Trailer brake LAMP switch X-381 Trailer Brake-CAB connection

82944111

MOIL12TR00202AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 36 CONNECTOR X-360 - Brake fluid level switch CONNECTOR X-360 - Brake fluid level switch PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER Wire harnesses - Electrical 1 300 (OR/BL) X-360Brake fluid level switch schematic frame 17 (55.100) X-001Engine - Cab connection 2 269 (RD) X-360Brake fluid level switch X-001Engine - Cab connection

82012083

MOIL12TR0483AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-362 - FUEL HEATER PIN WIRE NUMBER NUMBER 1 2 3 1247 (BK) 4

1251 (RD/YE)

CONNECTOR X-362 - FUEL HEATER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100) X-362FUEL HEATER X-420ENGINE EARTH X-362FUEL HEATER SP-086

MOIL12TR0484AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-363 - TRAILER BRAKE SOLENOID 1 CONNECTOR X-363 - TRAILER BRAKE SOLENOID 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 785 (Y/U)

X-363TRAILER BRAKE SOLENOID 1 SP-112

87680382

MOIL12TR00203AA

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Wire harnesses - Electrical schematic frame 24 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-365 - Clutch 4 PIN WIRE NUMBER NUMBER 1 49 (RD) 2

51 (BK/WH)

CONNECTOR X-365 - Clutch 4 CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

X-365Clutch 4 X-300Cab/Trans Split Wire harnesses - Electrical schematic frame 14 (55.100) Connector X-365Clutch 4 X-300Cab/Trans Split Connector

82012083

MOIL12TR00204AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-368 - Diff Lock Clutch SW CONNECTOR X-368 - Diff Lock Clutch SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 761 (RD/WH) 2

97 (GY/BL)

X-368Diff Lock Clutch SW X-300Cab/Trans Split Connector X-368Diff Lock Clutch SW SP-104

82012083

MOIL12TR0487AA

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-369 - CRPM +/- SW PIN NUMBER 1 2 3 4 5 6 7 8 9 10

WIRE NUMBER 213 (OR/WH) 205 (OR) 208 (OR/BL) 20 (BK) 142 (YE) 26 (BK) 81 (YE)

CONNECTOR X-369 - CRPM +/- SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-369CRPM +/- SW X-450ADIC CN1 Wire harnesses - Electrical schematic frame 16 (55.100) SP-090 X-369CRPM +/- SW X-369CRPM +/- SW X-450ADIC CN1 X-369CRPM +/- SW X-280GROUND SP-012 X-369CRPM +/- SW X-369CRPM +/- SW X-280GROUND SP-012 X-369CRPM +/- SW

84819781

MOIL12TR00205AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 37 CONNECTOR X-370 -Power Pdu-module connection CONNECTOR X-370 - Power Pdu-module connection PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 25 (R) X-007CAB Power Fuse X-370Power 686 (RD) Pdu-module connection X-370Main Harness/ Engine Power Connection SP-036

84153320

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Electrical systems - Harnesses and connectors

CONNECTOR X-372 - Air trailer brake pressure sensor CONNECTOR X-372 - Air trailer brake pressure sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 170 (BK/YE) 260 (BK/YE)

212 (WH) 234 (WH)

166 (BK) 250 (BK)

X-178air brake pressure sensor X-372Air brake X-377ADIC CN3 X-372Air trailer brake pressure sensor X-178air brake pressure sensor X-372Air brake X-372Air trailer brake pressure sensor SP-057 X-204Tecu X-180main-isobus connection SP-028 X-372Air trailer brake pressure sensor -

87687242

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Electrical systems - Harnesses and connectors

CONNECTOR X-374 - 4WD SW PIN NUMBER 1 2 3 4 5 6 7 8 9 10

WIRE NUMBER 633 (TQ/GN) 630 (GY/BL) 773 (TQ) 138 (BK) 1209 (YE) 239 (BK) 168 (YE)

CONNECTOR X-374 - 4WD SW CIRCUIT REFERENCE X-230XCM CN3-A X-3744WD SW SP-301L SP-303L X-3744WD SW X-230XCM CN3-A X-3744WD SW SP-022 SP-012 X-3744WD SW X-3744WD SW SP-022 X-016LH front headlamp SP-010

84819781

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

CONNECTOR X-375 - Diff. Lock SW PIN WIRE NUMBER NUMBER 1 261 (RD/GN) 2 3 4 5 6

256 (GY/BL) 251 (GY/BL) 254 (RD/YE)

7 8 9 10

165 (BK) 162 (YE) 178 (BK) 1213 (YE)

CONNECTOR X-375 - Diff. Lock SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-375Diff. Lock SW X-240XCM CN3-B SP-020 X-375Diff. Lock SW X-375Diff. Lock SW SP-020 X-375Diff. Lock SW X-240XCM CN3-B X-375Diff. Lock SW SP-022 SP-011 X-017RH front headlamp X-375Diff. Lock SW SP-022 SP-012 X-375Diff. Lock SW

84819781

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Electrical systems - Harnesses and connectors

CONNECTOR X-376 - Diagnostic Socket 1 CONNECTOR X-376 - Diagnostic Socket 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER A B C D E

841 801 824 825 148

F G

1293 (WH/BL)

H J

1065 (YE) 1075 (GN)

(BK) (OR/WH) (YE) (GN) (BR/WH)

X-376Diagnostic Socket 1 SP-022 X-376Diagnostic Socket 1 SP-030 SP-103H X-376Diagnostic Socket 1 SP-103L X-376Diagnostic Socket 1 X-376Diagnostic Socket 1 X-001Main Harness/ Engine Connection X-450ADIC CN1 X-376Diagnostic Socket 1 X-376Diagnostic Socket 1 SP-306H X-376Diagnostic Socket 1 SP-306L

87516075

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Electrical systems - Harnesses and connectors

CONNECTOR X-377 - ADIC CN3 PIN WIRE NUMBER NUMBER 1 154 (BR/RD) 2

791 (BR/BK)

792 (BR/VT)

807 (GY/BL)

260 (BK/YE)

CONNECTOR X-377 - ADIC CN3 CIRCUIT REFERENCE SP-011 X-013Head-lamp/engine harness connection X-378ISO 11786 Socket X-377ADIC CN3 X-378ISO 11786 Socket X-377ADIC CN3 X-378ISO 11786 Socket X-377ADIC CN3 X-377ADIC CN3 X-372Air trailer brake pressure sensor -

87710588

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

CONNECTOR X-378 - ISO 11786 Socket PIN WIRE NUMBER NUMBER 1 791 (BR/BK) 2

792 (BR/VT)

154 (BR/RD)

807 (GY/BL)

5 6 7

796 (OR/BL) 1290 (BK)

CONNECTOR X-378 - ISO 11786 Socket CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-378ISO 11786 Socket X-377ADIC CN3 X-378ISO 11786 Socket X-377ADIC CN3 SP-011 X-013Head-lamp/engine harness connection X-378ISO 11786 Socket X-377ADIC CN3 X-378ISO 11786 Socket SP-029 X-378ISO 11786 Socket SP-022

87357892

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 38 CONNECTOR X-380 - CAB-Mid mount-Front loader connection CONNECTOR X-380 - CAB-Mid mount-Front loader connection PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER Wire harnesses - Electrical 1 905 (BL) X-380Main Harness/ Front Loader schematic frame 23 (55.100) 906 (BL) Connection SP-108 X-380CAB-Mid mount-Front loader connection X-395Front_loader ready 7 POLES SOCKET X-392Front Loader Ready 2 282 (GN) Predisposition X-380Main Harness/ 867 (GN) Front Loader Connection X-380CAB-Mid mount-Front loader connection X-395Front_loader ready 7 POLES SOCKET 3 896 (RD) X-380Main Harness/ Front Loader 897 (RD) Connection X-392Front Loader Ready Predisposition X-380CAB-Mid mount-Front loader connection X-395Front_loader ready 7 POLES SOCKET X-120Modulo Relays R9-R16 + 4 713 (GY) Fuses F37-F40 X-380Main Harness/ 901 (GY) Front Loader Connection X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader connection 5 899 (YE) X-394Stoll Comfort Drive SW 900 (YE) X-380Main Harness/ Front Loader Connection X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader connection 6 898 (BR) X-393Stoll Tool Locking SW 902 (BR) X-380Main Harness/ Front Loader Connection X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader connection

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Electrical systems - Harnesses and connectors

MOIL13TR00107AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-381 - Trailer Brake-CAB connection CONNECTOR X-381 - Trailer Brake-CAB connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1193 (BK) 879 (B)

232 (WH) 273 (W)

846 (YE/BL) 880 (Y/U)

925 (BR/GY) 928 (N/S)

926 (N/W) 927 (BR/WH)

SP-028 X-381Main Harness/ Trailer Brake Connection X-359Trailer brake LAMP switch X-381Trailer Brake-CAB connection X-381Main Harness/ Trailer Brake Connection SP-057 X-399Trailer brake LAMP switch (2nd connector) X-381Trailer Brake-CAB connection X-381Main Harness/ Trailer Brake Connection SP-111 X-381Trailer Brake-CAB connection SP-112 SP-113 X-381Main Harness/ Trailer Brake Connection X-502Trailer Brake Safety switch 2 X-381Trailer Brake-CAB connection X-503Trailer Brake Safety switch 1 X-381Trailer Brake-CAB connection X-140Module R17-R24 Fuse 41-44 X-381Main Harness/ Trailer Brake Connection

87691924

MOIL12TR0493AA

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Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 24 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-384 - TRAILER BRAKE SOLENOID 2 CONNECTOR X-384 - TRAILER BRAKE SOLENOID 2 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 788 (Y/U)

X-384TRAILER BRAKE SOLENOID 2 SP-112

87680382

MOIL12TR00209AA

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Wire harnesses - Electrical schematic frame 24 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-385 - Main Circuit Connection 2 CONNECTOR X-385 - Main Circuit Connection 2 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1048 (TQ/BK) 560 (TQ/BK)

624 (BL) 625 (BL)

1150 (YE/BK) 706 (YE/BK)

1079 (RD/YE) 986 (RD/YE)

1229 (WH/RD) 1258 (WH/RD)

1232 (WH/BL) 1259 (WH/BL)

1078 (RD/BK) 930 (RD/BK)

1261 (VT/BK) 1292 (VT/BK)

1221 (GN) 1222 (GN)

SP-050 X-385Main Harness/ Roof Connection X-021LH Front Lamp X-385Main Circuit Connection 2 X-075Front Wiper Motor Openable X-385Main Circuit Connection 2 SP-056 X-385Main Harness/ Roof Connection X-385Main Circuit Connection 2 SP-042 SP-058 X-385Main Harness/ Roof Connection X-385Main Harness/ Roof Connection SP-051A X-385Main Circuit Connection 2 SP-098 X-385Main Circuit Connection 2 SP-013 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-385Main Harness/ Roof Connection X-034Lights SW X-385Main Circuit Connection 2 X-091Light Control SW X-385Main Harness/ Roof Connection SP-050A X-385Main Harness/ Roof Connection X-385Main Circuit Connection 2 SP-097 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-385Main Harness/ Roof Connection X-034Lights SW X-385Main Circuit Connection 2 SP-019 X-385Main Harness/ Roof Connection X-075Front Wiper Motor Openable X-385Main Circuit Connection 2

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Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100)

Electrical systems - Harnesses and connectors

MOIL12TR0494AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-386 - LH Rear SMV PIN WIRE NUMBER NUMBER 1 935 (RD/BK) 2 172 (BK)

CONNECTOR X-386 - LH Rear SMV CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-386LH Rear SMV SP-097 X-386LH Rear SMV X-403Roof Ground 2

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Wire harnesses - Electrical schematic frame 07 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-387 - RH Rear SMV PIN WIRE NUMBER NUMBER 1 1304 (RD/YE) 2 508 (BK)

CONNECTOR X-387 - RH Rear SMV CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-387RH Rear SMV SP-098 X-387RH Rear SMV X-403Roof Ground 2

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Wire harnesses - Electrical schematic frame 07 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-389 - Reverse alarm PIN WIRE NUMBER NUMBER 1 1262 (BL/YE) 252 (BL/YE) 2

1107 (BK) 274 (BK)

1291 (YE)

CONNECTOR X-389 - Reverse alarm CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-120Modulo Relays R9-R16 + Fuses F37-F40 X-389Reverse Alarm X-389Reverse alarm SP-501 X-400Fuse Box Ground 1 X-389Reverse Alarm X-389Reverse alarm SP-502 X-389Reverse Alarm SP-012

87680689

MOIL12TR00210AA

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Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 39 CONNECTOR X-392 - Front loader ready predisposition JUMPER CONNECTOR X-392 - Front loader ready predisposition JUMPER PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER Wire harnesses - Electrical X-392Front loader ready 1 903 (R/G) predisposition JUMPER X-295Diode schematic frame 23 (55.100) 907 (BL) X-392Front Loader Ready Predisposition SP-108 X-392Front Loader Ready 2 282 (GN) Predisposition X-380Main Harness/ 904 (G) Front Loader Connection X-392Front loader ready predisposition JUMPER SA1 3 896 (RD) X-380Main Harness/ Front Loader Connection X-392Front Loader Ready Predisposition X-120Modulo Relays R9-R16 + 4 711 (GN/WH) Fuses F37-F40 X-392Front Loader 909 (G) Ready Predisposition X-392Front loader ready predisposition JUMPER SA1

87680652

MOIL12TR00211AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-393 - Stoll Tool Locking SW CONNECTOR X-393 - Stoll Tool Locking SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1116 (OR/WH) 2 898 (BR)

910 (BK)

SP-073 X-393Stoll Tool Locking SW X-393Stoll Tool Locking SW X-380Main Harness/ Front Loader Connection X-393Stoll Tool Locking SW SP-022

87691928

MOIL12TR00212AA

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Wire harnesses - Electrical schematic frame 23 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-394 - Stoll Comfort Drive SW CONNECTOR X-394 - Stoll Comfort Drive SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1115 (OR/WH) 2 899 (YE)

911 (BK)

SP-073 X-394Stoll Comfort Drive SW Wire harnesses - Electrical schematic frame 23 (55.100) X-394Stoll Comfort Drive SW X-380Main Harness/ Front Loader Connection X-394Stoll Comfort Drive SW SP-022

87680689

MOIL12TR00213AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-395 - Front_loader ready 7 POLES SOCKET CONNECTOR X-395 - Front_loader ready 7 POLES SOCKET WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 906 (BL)

867 (GN)

897 (RD)

901 (GY)

900 (YE)

902 (BR)

Wire harnesses - Electrical X-380CAB-Mid mount-Front loader connection X-395Front_loader ready schematic frame 23 (55.100) 7 POLES SOCKET X-380CAB-Mid mount-Front loader connection X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader connection X-395Front_loader ready 7 POLES SOCKET X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader connection X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader connection X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader connection

84185564

MOIL13TR00108AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-396 - EHR 1 PIN NUMBER 1 2 3 4

WIRE NUMBER 832 850 839 836

(YE/GN) (BL) (RD) (BK/WH)

CONNECTOR X-396 - EHR 1 CIRCUIT REFERENCE

Wire harnesses - Electrical schematic frame 11 (55.100)

X-396EHR 1 SP-140 X-396EHR 1 SP-116 X-396EHR 1 SP-117 SP-175 X-396EHR 1

MOIL12TR00234AA

MOIL12TR00214AA

ELECTRICAL SCHEMATIC FRAME

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Electrical systems - Harnesses and connectors

CONNECTOR X-397 - EHR 2 PIN NUMBER 1 2 3 4

WIRE NUMBER 833 860 837 834

(YE/GN) (BL) (RD) (BK/WH)

CONNECTOR X-397 - EHR 2 CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 11 (55.100)

X-397EHR 2 SP-140 X-397EHR 2 SP-141 X-397EHR 2 SP-142 SP-175 X-397EHR 2

MOIL12TR00234AA

MOIL12TR00215AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-398 - Can Resistor Connector CONNECTOR X-398 - Can Resistor Connector WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 830 (BK/YE) 2

653 (BL)

766 (RD)

835 (BK/WH)

SP-140 X-398Can Resistor Connector X-398Can Resistor Connector SP-141 X-398Can Resistor Connector SP-142 SP-175 X-398Can Resistor Connector

87687242

MOIL12TR00216AA

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Wire harnesses - Electrical schematic frame 11 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-399 - Trailer brake LAMP switch (2nd connector) CONNECTOR X-399 - Trailer brake LAMP switch (2nd connector) WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 273 (W)

X-399Trailer brake LAMP switch (2nd Wire harnesses - Electrical connector) X-381Trailer Brake-CAB schematic frame 17 (55.100) connection

82944111

MOIL12TR00217AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 40 CONNECTOR X-400 - Fuse Box Ground 1 PIN WIRE NUMBER NUMBER 1 186 (BK) 3 639 (BK) 4

636 (BK)

453 (BK)

449 (BK)

726 (BK)

727 (BK)

550 (BK)

719 (BK)

521 (BK)

647 (BK)

1107 (BK)

14 15

646 (BK) 950 (BK)

CONNECTOR X-400 - Fuse Box Ground 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-023 X-400Fuse Box Ground 1 X-400Fuse Box Ground 1 X-077Rear Wiper Washer Pump X-076Front Wiper Washer Pump X-400Fuse Box Ground 1 X-400Fuse Box Ground 1 X-046LH Fan X-400Fuse Box Ground 1 X-047RH Fan X-0268A Socket X-400Fuse Box Ground 1 X-029Electrical Seat X-400Fuse Box Ground 1 X-023LH Rear Lamp X-400Fuse Box Ground 1 X-400Fuse Box Ground 1 X-100Main harness/armrest connection X-024RH Rear Lamp X-400Fuse Box Ground 1 X-027Cigar Lighter Base X-400Fuse Box Ground 1 X-400Fuse Box Ground 1 X-389Reverse Alarm X-400Fuse Box Ground 1 SP-026 X-090Flasher X-400Fuse Box Ground 1

84153306

MOIL12TR0495AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-402 - 40A Socket ISO 2 PIN WIRE NUMBER NUMBER 1 180 (BK)

CONNECTOR X-402 - 40A Socket ISO 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-026 X-40240A Socket ISO 2

87680382

MOIL12TR00218AA

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Wire harnesses - Electrical schematic frame 09 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-403 - Roof Ground 2 PIN WIRE NUMBER NUMBER 1 172 (BK) 2

141 (BK)

604 (BK)

599 (BK)

596 (BK)

509 (BK)

520 (BK)

153 (BK)

511 (BK)

510 (BK)

499 (BK)

477 (BK)

476 (BK)

474 (BK)

601 (BK)

16 17

438 (BK) 494 (BK)

CONNECTOR X-403 - Roof Ground 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-386LH Rear SMV X-403Roof Ground 2 X-306RH Rear Work Lamp 2 X-403Roof Ground 2 X-403Roof Ground 2 X-036Rear Wiper and Washer SW X-075Front Wiper Motor Openable X-403Roof Ground 2 X-038Rear Wiper X-403Roof Ground 2 X-022RH Front lamp X-403Roof Ground 2 X-021LH Front Lamp X-403Roof Ground 2 X-307LH Rear Work Lamp 2 X-403Roof Ground 2 X-403Roof Ground 2 X-059RH Grab Rail Work Lamp X-403Roof Ground 2 X-060LH Grab Rail Work Lamp X-403Roof Ground 2 X-054Spot Lamp X-058LH Front Roof Lamp X-403Roof Ground 2 X-056LH Rear Work Lamp X-403Roof Ground 2 X-057RH Front Roof Lamp X-403Roof Ground 2 X-403Roof Ground 2 X-071RH Beacon Socket/ Extension X-150 X-403Roof Ground 2 X-061Change Over SW X-403Roof Ground 2

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Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100)

Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 18 451 (BK) 19 455 (BK) 20 473 (BK) 21

475 (BK)

606 (BK)

611 (BK)

24 25 26 27 28

644 665 666 667 762

763 (BK)

30 31

1238 (BK) 378 (BK)

508 (BK)

522 (BK)

3 (BK)

(BK) (BK) (BK) (BK) (BK)

CONNECTOR X-403 - Roof Ground 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-031A/C SW X-403Roof Ground 2 SP-007 H-004BHorn X-052Roof Lamp 2 X-403Roof Ground 2 X-403Roof Ground 2 X-055RH Rear Work Lamp X-403Roof Ground 2 X-032Beacon SW X-403Roof Ground 2 X-073LH Beacon Socket/ Extension X-039Radio X-403Roof Ground 2 X-150 X-403Roof Ground 2 X-150 X-403Roof Ground 2 X-403Roof Ground 2 X-150 X-096LH License Plate Lamp X-403Roof Ground 2 X-097RH License Plate Lamp X-403Roof Ground 2 X-034Lights SW X-403Roof Ground 2 X-021ALH Front Lamp X-403Roof Ground 2 X-387RH Rear SMV X-403Roof Ground 2 X-022ARH Front lamp X-403Roof Ground 2 X-115BImplement Socket J-001

84153306

MOIL13TR00109AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 41 CONNECTOR X-410 - Steering Column Ground CONNECTOR X-410 - Steering Column Ground PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 40 (BK) X-250Home-Enter SW X-410Steering Wire harnesses - Electrical schematic frame 05 (55.100) Wire Column Ground harnesses - Electrical schematic 2 43 (BK) X-201in cab connector SP-307 frame 08 (55.100) Wire harnesses 3 626 (BK) X-410Steering Column Ground - Electrical schematic frame 09 X-074Front Wiper Motor Fixed (55.100) Wire harnesses - Electrical 5 294 (BK) X-460ADIC CN2 X-410Steering schematic frame 16 (55.100) Wire Column Ground 6 76 (BK) X-250Home-Enter SW X-410Steering harnesses - Electrical schematic frame 17 (55.100) Wire harnesses Column Ground - Electrical schematic frame 22 7 63 (BK) X-260UP-Down SW X-410Steering (55.100) Column Ground 8 66 (BK) X-260UP-Down SW X-410Steering Column Ground 9 82 (BK) X-260UP-Down SW X-410Steering Column Ground 10 457 (BK) X-045A/C ECU X-410Steering Column Ground 11 443 (BK) X-044Thermostat No Frost A/C X-410Steering Column Ground 13 X-048Wiper Motor Timer 1218 (BK) X-410Steering Column Ground 14 949 (BK) X-092Hazard SW X-410Steering Column Ground 15 569 (BK) X-098Main/ 7 Pole Socket Extension X-410Steering Column Ground

84153309

MOIL12TR0496AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 42 CONNECTOR X-420 - ENGINE EARTH PIN WIRE NUMBER NUMBER 1 44 (BK) 2 1033 (BK) 3

313 (BK)

335 (BK)

311 (BK)

312 (BK)

206 (BK)

576 (BK)

1247 (BK)

CONNECTOR X-420 - ENGINE EARTH CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-004 X-420ENGINE EARTH X-025HOOD lights connection X-420ENGINE EARTH X-420ENGINE EARTH X-937EDC17 CONNECTOR 2 X-950Water in fuel X-420ENGINE EARTH X-420ENGINE EARTH X-937EDC17 CONNECTOR 2 X-420ENGINE EARTH X-937EDC17 CONNECTOR 2 X-025HOOD lights connection X-420ENGINE EARTH X-088A/C compressor X-420ENGINE EARTH X-362FUEL HEATER X-420ENGINE EARTH

84237741

MOIL13TR00059AA

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Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 45 CONNECTOR X-450 - ADIC CN1 PIN WIRE NUMBER NUMBER 1 263 (GN) 2 303 (BR) 3 4 5

1050 (YE) 1051 (GN) 34 (WH/BK)

6 7

265 (BK) 225 (WH)

8 9

226 (RD) 270 (GY)

10 11 12 13 14 15 16 17 18 19 20

231 (BK/WH) 208 (OR/BL) 213 (OR/WH) 1250 (OR/BK) 1263 (OR/WH) 240 (PK/BK)

241 (WH/BK)

22 23 24 25

242 (BR/BK) 243 (BL/BK) 1293 (WH/BL)

1277 (TQ/WH)

CONNECTOR X-450 - ADIC CN1 CIRCUIT REFERENCE X-450ADIC CN1 X-355Seat SW X-450ADIC CN1 X-300Main Harness/ Trasmission Connection SP-101H X-450ADIC CN1 SP-101L X-450ADIC CN1 X-321Foot Pedal Sensor SW X-450ADIC CN1 SP-028 X-450ADIC CN1 X-013Head-lamp/engine harness connection H-004AHorn X-324Hand Throttle X-450ADIC CN1 X-356Brakes Not Latched SW X-450ADIC CN1 X-324Hand Throttle X-450ADIC CN1 X-369CRPM +/- SW X-450ADIC CN1 X-369CRPM +/- SW X-450ADIC CN1 X-090Flasher X-450ADIC CN1 X-090Flasher X-450ADIC CN1 X-250Home-Enter SW X-450ADIC CN1 X-250Home-Enter SW X-450ADIC CN1 X-260UP-Down SW X-450ADIC CN1 X-260UP-Down SW X-450ADIC CN1 X-450ADIC CN1 X-376Diagnostic Socket 1 X-001Main Harness/ Engine Connection X-450ADIC CN1

82028493

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100)

Electrical systems - Harnesses and connectors

MOIL12TR0497AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 46 CONNECTOR X-460 - ADIC CN2 PIN WIRE NUMBER NUMBER 1 11 (TQ) 2 3

1278 (GY/BL) 292 (YE)

4 5 6 7 8

1144 (GN) 93 (OR/TQ) 1188 (RD)

9 10 11 12 13

1093 (RD/BK) 1094 (RD/YE) 296 (WH) 1279 (RD/GN)

14 15

228 (TQ) 294 (BK)

16 17 18

1097 (BL/YE) 290 (RD)

19 20 21 22 23 24 25 26

1096 (YE) 293 (OR/WH) 291 (OR/BL) 1071 (GN/WH) 96 (OR/BK)

CONNECTOR X-460 - ADIC CN2 CIRCUIT REFERENCE X-460ADIC CN2 X-321Foot Pedal Sensor SW X-460ADIC CN2 X-197BDS SW X-460ADIC CN2 X-001Main Harness/ Engine Connection SP-100 X-460ADIC CN2 SP-011 X-016LH front headlamp X-358Handbrake SW X-460ADIC CN2 X-460ADIC CN2 SP-050A X-460ADIC CN2 SP-051A X-460ADIC CN2 SP-057 X-001Main Harness/ Engine Connection X-460ADIC CN2 X-324Hand Throttle X-460ADIC CN2 X-460ADIC CN2 X-410Steering Column Ground SP-008 X-460ADIC CN2 X-460ADIC CN2 X-001Main Harness/ Engine Connection X-460ADIC CN2 SP-012 X-460ADIC CN2 SP-030 X-460ADIC CN2 SP-029 X-460ADIC CN2 SP-172 X-460ADIC CN2 X-303CRPM 1/2 &amp; ON/OFF SW

82016219

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100)

Electrical systems - Harnesses and connectors

MOIL12TR0498AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 50 CONNECTOR X-500 - + Battery PIN WIRE NUMBER NUMBER 1 106 (BL) 2B (BK)

CONNECTOR X-500 - + Battery CIRCUIT REFERENCE X-500 X-552KAM Fuse X-500+ Battery X-009BDS

82863787

MOIL13TR00110AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-501 - 40A Socket ISO 1 PIN WIRE NUMBER NUMBER 1 175 (BL) 2 201 (YE)

CONNECTOR X-501 - 40A Socket ISO 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical X-50140A Socket ISO 1 SP-017 schematic frame 09 (55.100) X-50140A Socket ISO 1 X-130Modulo Fuses F1-F32

84015523

MOIL12TR00219AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-502 - Trailer Brake Safety switch 2 CONNECTOR X-502 - Trailer Brake Safety switch 2 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 928 (N/S)

Wire harnesses - Electrical X-502Trailer Brake Safety switch 2 X-381 Trailer Brake-CAB connection schematic frame 24 (55.100)

82944111

MOIL12TR00220AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-503 - Trailer Brake Safety switch 1 CONNECTOR X-503 - Trailer Brake Safety switch 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 926 (N/W)

Wire harnesses - Electrical X-503Trailer Brake Safety switch 1 X-381 Trailer Brake-CAB connection schematic frame 24 (55.100)

82944111

MOIL12TR00221AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-504 - Creeper RAIL SW PIN WIRE NUMBER NUMBER 1 101 (WH/GN) 2

103 (WH)

CONNECTOR X-504 - Creeper RAIL SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-188Cab/Trans Split Connector X-504Creeper RAIL SW SP-146 X-504Creeper RAIL SW

87691973

MOIL13TR00111AA

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-509 - Key SW 30 PIN WIRE NUMBER NUMBER 1 258 (RD)

CONNECTOR X-509 - Key SW 30 CIRCUIT REFERENCE X-509Key SW 30 X-130Modulo Fuses F1-F32

87747155

MOIL12TR0500AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 02 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 51 CONNECTOR X-510 - Key SW 15 PIN WIRE NUMBER NUMBER 5 690 (BR) 6 691 (BR) 9 679 (GY)

CONNECTOR X-510 - Key SW 15 CIRCUIT REFERENCE X-510Key SW 15 SP-176 X-510Key SW 15 SP-176 X-510Key SW 15 X-130Modulo Fuses F1-F32

MOIL12TR00939AA

MOIL12TR0501AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 02 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 52 CONNECTOR X-522 - Creeper NOT-RAIL SW CONNECTOR X-522 - Creeper NOT-RAIL SW PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 102 (BK/WH) X-188Cab/Trans Split Connector X-522Creeper NOT-RAIL SW 2 304 (WH) X-522Creeper NOT-RAIL SW SP-146

82012083

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 53 CONNECTOR X-533 - ENGINE MAXI-RELAY MODULE CONNECTOR X-533 - ENGINE MAXI-RELAY MODULE PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER R1_30 17 (RD/BK) SP-001 X-533ENGINE MAXI-RELAY Wire harnesses - Electrical schematic frame 01 (55.100) MODULE R1_85 26 (BK) X-369CRPM +/- SW X-280GROUND R1_86 25 (BL/YE) X-007CAB Power Fuse X-370Power Pdu-module connection R1_87 840 (RD/YE) X-002PDU connection X-533ENGINE MAXI-RELAY MODULE R2_30 277 (RD) SP-001 X-533ENGINE MAXI-RELAY MODULE R2_85 18 (BK/WH) X-012Interconnect Transmission / Trailer Socket J-003Trailer Socket ISO R2_86 13 (RD/BK) SP-001 X-533ENGINE MAXI-RELAY MODULE R2_87 14 (RD) X-533ENGINE MAXI-RELAY MODULE SP-002

84405124

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Electrical systems - Harnesses and connectors

CONNECTOR X-534 - EDC Led Panel PIN WIRE NUMBER NUMBER 1 89 (OR/BL) 2 90 (PK/BK) 3

92 (PK/WH)

4 7 8

91 (PK) 99 (BK/YE) 87 (BK/YE)

CONNECTOR X-534 - EDC Led Panel CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-007 X-017RH front headlamp X-534EDC Led Panel X-220XCM CN2 X-534EDC Led Panel X-220XCM CN2 SP-007 X-016LH front headlamp X-534EDC Led Panel SP-068 X-534EDC Led Panel SP-068

87680680

MOIL12TR00222AA

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Wire harnesses - Electrical schematic frame 03 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 55 CONNECTOR X-551 - BDS Set Diode PIN WIRE NUMBER NUMBER 1 1298 (BL/YE) 2 1502 (YE)

CONNECTOR X-551 - BDS Set Diode CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-551BDS Set Diode SP-008 SP-150 X-551BDS Set Diode

84121648

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Electrical systems - Harnesses and connectors

CONNECTOR X-552 - KAM Fuse PIN WIRE NUMBER NUMBER 1 164 (BL) 2

106 (BL)

CONNECTOR X-552 - KAM Fuse CIRCUIT REFERENCE X-203SWCD display X-180mainisobus connection X-500 X-552KAM Fuse

84175724

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

CONNECTOR X-553 - UP shift switch PIN WIRE NUMBER NUMBER 2 855 (OR/WH) 4 638 (BL)

CONNECTOR X-553 - UP shift switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-553UP shift switch SP-099 X-553UP shift switch SP-153

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Electrical systems - Harnesses and connectors

CONNECTOR X-554 - Down shift switch PIN WIRE NUMBER NUMBER 2 864 (OR/WH) 4 784 (OR/TQ)

CONNECTOR X-554 - Down shift switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-554Down shift switch SP-099 X-554Down shift switch SP-154

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Electrical systems - Harnesses and connectors

CONNECTOR X-555 - Dump clutch switch CONNECTOR X-555 - Dump clutch switch WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 2 882 (OR/WH) 4 814 (PK/WH)

X-555Dump clutch switch SP-099 X-555Dump clutch switch SP-155

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Electrical systems - Harnesses and connectors

CONNECTOR X-556 - Reverse light 1 PIN WIRE NUMBER NUMBER 1 257 (BL/YE) 2 275 (BK)

CONNECTOR X-556 - Reverse light 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-501 X-556Reverse light 1 SP-502 X-556Reverse light 1

82012083

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Electrical systems - Harnesses and connectors

CONNECTOR X-557 - Buzzer PIN WIRE NUMBER NUMBER 1 1267 (BL/YE) 2 278 (BK)

CONNECTOR X-557 - Buzzer CIRCUIT REFERENCE SP-501 X-557Buzzer SP-502 X-557Buzzer

82012083

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

CONNECTOR X-558 - Reverse light 2 PIN WIRE NUMBER NUMBER 1 259 (BL/YE) 2 279 (BK)

CONNECTOR X-558 - Reverse light 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-501 X-558Reverse light 2 SP-502 X-558Reverse light 2

82012083

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 60 CONNECTOR X-601 - Breakaway Connector 1 CONNECTOR X-601 - Breakaway Connector 1 PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 973 (BK) SP-166 X-601Breakaway Connector Wire harnesses - Electrical schematic frame 13 (55.100) 1 2 971 (BK/WH) X-601Breakaway Connector 1 SP-166 3 X-602Ecu power Relay 968 (BL) X-601Breakaway Connector 1 4 X-603Implement Power Relay 967 (RD) X-601Breakaway Connector 1

87533827

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Electrical systems - Harnesses and connectors

CONNECTOR X-602 - Ecu power Relay PIN WIRE NUMBER NUMBER 1 978 (OR) 2 3

972 (BK) 965 (BL)

968 (BL)

CONNECTOR X-602 - Ecu power Relay CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-660external Isobus X-602Ecu power Relay X-602Ecu power Relay SP-166 X-606Ecu Power Fuse X-602Ecu power Relay X-602Ecu power Relay X-601Breakaway Connector 1

MOIL12TR00940AA

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-603 - Implement Power Relay CONNECTOR X-603 - Implement Power Relay WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 30 966 (RD) 85

970 (BK)

977 (OR/BK)

967 (RD)

X-607Implement Power Fuse X-603Implement Power Relay X-603Implement Power Relay SP-166 X-660external Isobus X-603Implement Power Relay X-603Implement Power Relay X-601Breakaway Connector 1

87692853

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-605 - Isobus Power Ground CONNECTOR X-605 - Isobus Power Ground WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1061 (BK)

X-605Isobus Power Ground SP-166

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-606 - Ecu Power Fuse PIN WIRE NUMBER NUMBER 1 964 (BL) 2 965 (BL)

CONNECTOR X-606 - Ecu Power Fuse CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-606Ecu Power Fuse SP-165 X-606Ecu Power Fuse X-602Ecu power Relay

MOIL12TR00941AA

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-607 - Implement Power Fuse CONNECTOR X-607 - Implement Power Fuse WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 963 (RD) 2 966 (RD)

SP-165 X-607Implement Power Fuse Wire harnesses - Electrical schematic frame 13 (55.100) X-607Implement Power Fuse X-603Implement Power Relay

MOIL12TR00941AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-608 - Isobus Power Supply CONNECTOR X-608 - Isobus Power Supply WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1060 (RD)

X-608Isobus Power Supply SP-165

84153309

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 65 CONNECTOR X-657 - Breakaway Connector 2 CONNECTOR X-657 - Breakaway Connector 2 PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER Wire harnesses - Electrical 1 933 (RD) X-657Breakaway Connector 2 schematic frame 13 (55.100) X-660external Isobus 2 829 (WH) X-657Breakaway Connector 2 X-660external Isobus 3 934 (BK) X-657Breakaway Connector 2 X-660external Isobus 4 168 (GN) X-016LH front headlamp SP-010

87708147

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 66 CONNECTOR X-660 - external Isobus PIN WIRE NUMBER NUMBER 1 1032 (BK) 934 (BK)

1031 (RD) 933 (RD)

829 (WH) 936 (YE)

168 (GN) 974 (GN)

977 (OR/BK) 980 (OR/BK)

978 (OR) 981 (OR)

CONNECTOR X-660 - external Isobus CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical X-180MAIN-ISOBUS Connector schematic frame 13 (55.100) X-660Main Harness/ ISOBUS Connection to External CAB X-657Breakaway Connector 2 X-660external Isobus X-180MAIN-ISOBUS Connector X-660Main Harness/ ISOBUS Connection to External CAB X-657Breakaway Connector 2 X-660external Isobus X-657Breakaway Connector 2 X-660external Isobus X-660Main Harness/ ISOBUS Connection to External CAB SP-306H X-016LH front headlamp SP-010 X-660Main Harness/ ISOBUS Connection to External CAB SP-306L X-660external Isobus X-603Implement Power Relay X-660Main Harness/ ISOBUS Connection to External CAB X-180MAIN-ISOBUS Connector X-660external Isobus X-602Ecu power Relay X-660Main Harness/ ISOBUS Connection to External CAB X-180MAIN-ISOBUS Connector

87691968

MOIL12TR00226AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 80 CONNECTOR X-806 - Clutch 1 PIN WIRE NUMBER NUMBER 1 456 (VT) 2 461 (BK/YE)

CONNECTOR X-806 - Clutch 1 CIRCUIT REFERENCE SP-008 X-015Corner light RH. SP-008 X-014LH corner light

82012083

MOIL12TR00227AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-807 - Clutch 2 PIN WIRE NUMBER NUMBER 1 481 (GN/WH) 2

479 (GN/BK)

CONNECTOR X-807 - Clutch 2 CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

X-807Clutch 2 X-300Cab/Trans Split Wire harnesses - Electrical schematic frame 14 (55.100) Connector X-807Clutch 2 X-300Cab/Trans Split Connector

82012083

MOIL12TR00228AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 89 CONNECTOR X-890 - Battery Positive Stud PIN WIRE NUMBER NUMBER 1 1 (BK)

CONNECTOR X-890 - Battery Positive Stud CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-892Battery Negative Stud X-893Boost Terminal Negative

82863787

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Electrical systems - Harnesses and connectors

CONNECTOR X-891 - Starter Motor PIN WIRE NUMBER NUMBER 1 1 (BK)

CONNECTOR X-891 - Starter Motor CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-892Battery Negative Stud X-893Boost Terminal Negative

82013012

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Electrical systems - Harnesses and connectors

CONNECTOR X-892 - Battery Negative Stud CONNECTOR X-892 - Battery Negative Stud WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1 (B)

X-892Battery Negative Stud X-893Boost Terminal Negative

82032329

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Electrical systems - Harnesses and connectors

CONNECTOR X-893 - Boost Terminal Negative CONNECTOR X-893 - Boost Terminal Negative WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1 (B)

X-892Battery Negative Stud X-893Boost Terminal Negative

82013012

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 93 CONNECTOR X-937 - EDC17 CONNECTOR 2 CONNECTOR X-937 - EDC17 CONNECTOR 2 PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER Wire harnesses - Electrical 1 1276 (RD/BK) X-937EDC17 CONNECTOR 2 schematic frame 18 (55.100) X-002PDU connection 2 311 (BK) X-420ENGINE EARTH X-937EDC17 CONNECTOR 2 3 1275 (RD/YE) X-937EDC17 CONNECTOR 2 X-002PDU connection 4 312 (BK) X-420ENGINE EARTH X-937EDC17 CONNECTOR 2 5 1274 (RD/YE) X-937EDC17 CONNECTOR 2 X-002PDU connection 6 313 (BK) X-420ENGINE EARTH X-937EDC17 CONNECTOR 2 7 314 (GN) X-937EDC17 CONNECTOR 2 X-943Lambda sonde 8 1281 (BR/WH) X-937EDC17 CONNECTOR 2 X-001Engine - Cab connection 9 10 11 12 13 14 329 (YE/BK) X-937EDC17 CONNECTOR 2 X-947Diff pressure sensor 15 16 17 18 19 327 (OR) X-937EDC17 CONNECTOR 2 X-942Air Temp intake 20 328 (OR/BK) X-937EDC17 CONNECTOR 2 X-942Air Temp intake 21 22 334 (BR/YE) X-937EDC17 CONNECTOR 2 X-949Jumper Engine1-Engine2 23 24 1069 (YE) X-001Engine - Cab connection X-937EDC17 CONNECTOR 2 25 1068 (GN) X-001Engine - Cab connection X-937EDC17 CONNECTOR 2 26 27 28 1273 (BK/WH) X-937EDC17 CONNECTOR 2 X-002PDU connection 29 30 347 (YE) X-950Water in fuel X-937EDC17 CONNECTOR 2 31

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Electrical systems - Harnesses and connectors

CONNECTOR X-937 - EDC17 CONNECTOR 2 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 32 33 34 35 36

330 (YE/BR)

37 38 39 40 41

333 (BL/RD)

42 43 44 45 46 47 48 49 50 51 52

332 (GY)

53 54

341 (OR)

55 56 57 58

331 (YE)

59 60 61 62

X-937EDC17 CONNECTOR 2 X-947Diff pressure sensor X-937EDC17 CONNECTOR 2 X-949Jumper Engine1-Engine2 X-937EDC17 CONNECTOR 2 X-949Jumper Engine1-Engine2 X-937EDC17 CONNECTOR 2 SP-031 X-937EDC17 CONNECTOR 2 X-947Diff pressure sensor -

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Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-937 - EDC17 CONNECTOR 2 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 63 315 (BR) 64

316 (OR)

65 66 67 68 69 70

1249 (GN)

71 72 73 74 75 76 77 78 79

323 (BR/GN)

324 (BR/YE)

325 (BK)

326 (BK/WH)

320 (BK/WH)

322 (GN/WH)

317 (GY)

318 (YE)

87 88 89 90 91 92 93 94

X-937EDC17 CONNECTOR 2 X-943Lambda sonde X-937EDC17 CONNECTOR 2 X-943Lambda sonde X-001Engine - Cab connection X-937EDC17 CONNECTOR 2 X-937EDC17 CONNECTOR 2 X-946Temp exhaust 1 X-937EDC17 CONNECTOR 2 X-946Temp exhaust 1 X-937EDC17 CONNECTOR 2 X-949Jumper Engine1-Engine2 X-937EDC17 CONNECTOR 2 X-949Jumper Engine1-Engine2 X-937EDC17 CONNECTOR 2 X-945Temp Exhaust 2 X-937EDC17 CONNECTOR 2 X-945Temp Exhaust 2 X-937EDC17 CONNECTOR 2 X-943Lambda sonde X-937EDC17 CONNECTOR 2 X-943Lambda sonde -

87745798

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Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

MOIL12TR0506AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-938 - Glow plugs PIN WIRE NUMBER NUMBER 1 366 (R/G) 2

384 (R)

436 (N/Y)

24 (O/W)

5 6

1020 (B) 365 (R/Y)

377 (R/B)

678 (S)

CONNECTOR X-938 - Glow plugs CIRCUIT REFERENCE X-938Glow plugs X-941 62 pin FPT interface X-938Glow plugs X-941 62 pin FPT interface X-938Glow plugs X-949Jumper Engine1-Engine2 X-938Glow plugs X-006Glow Plugs Power Fuse X-938Glow plugs SP-138 X-938Glow plugs X-941 62 pin FPT interface X-941 62 pin FPT interface X-938Glow plugs X-938Glow plugs X-949Jumper Engine1-Engine2

84356962

MOIL12TR0507AA

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-939 - EDC17 CONNECTOR 1 CONNECTOR X-939 - EDC17 CONNECTOR 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 427 (TQ/B) 2

428 (TQ/G)

3 4

391 (B)

5 6

392 (B/W)

7 8

393 (B/Y)

394 (G)

395 (G/B)

396 (G/W)

397 (G/Y)

398 (N)

399 (N/B)

400 (N/G)

429 (TQ/W)

430 (TQ/Y)

18 19 20

Wire harnesses - Electrical X-939EDC17 CONNECTOR 1 schematic frame 19 (55.100) X-940Injectors X-939EDC17 CONNECTOR 1 X-940Injectors X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-940Injectors X-939EDC17 CONNECTOR 1 X-940Injectors -

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Electrical systems - Harnesses and connectors

CONNECTOR X-939 - EDC17 CONNECTOR 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 21 22 23 401 (N/W) 24

402 (N/Y)

403 (O)

404 (O/B)

405 (O/TQ)

406 (O/U)

29 30 31

431 (W)

432 (W/O)

33 34

407 (O/W)

408 (TQ)

36 37

409 (TQ/G)

410 (TQ/W)

411 (R)

412 (R/B)

Wire harnesses - Electrical schematic frame 19 (55.100) X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-940Injectors X-939EDC17 CONNECTOR 1 X-940Injectors X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface

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Electrical systems - Harnesses and connectors

CONNECTOR X-939 - EDC17 CONNECTOR 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 41 413 (R/G) 42 43

414 (R/U)

415 (W)

45 46

433 (Y/B)

47 48

434 (Y/R)

416 (R/Y)

418 (S)

51 52 53

419 (S/B)

54 55

420 (S/G)

56 57

421 (S/R)

422A (S/TQ)

423 (R)

424 (S/W)

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Electrical systems - Harnesses and connectors

MOIL12TR0508AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 94 CONNECTOR X-940 - Injectors PIN WIRE NUMBER NUMBER A 429 (TQ/W) B

432 (W/O)

431 (W)

427 (TQ/B)

430 (TQ/Y)

434 (Y/R)

433 (Y/B)

428 (TQ/G)

J K

CONNECTOR X-940 - Injectors CIRCUIT REFERENCE X-939EDC17 CONNECTOR X-940Injectors X-939EDC17 CONNECTOR X-940Injectors X-939EDC17 CONNECTOR X-940Injectors X-939EDC17 CONNECTOR X-940Injectors X-939EDC17 CONNECTOR X-940Injectors X-939EDC17 CONNECTOR X-940Injectors X-939EDC17 CONNECTOR X-940Injectors X-939EDC17 CONNECTOR X-940Injectors -

87698252

MOIL12TR0509AA

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1 1 1 1 1 1 1 1

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-941 - 62 pin FPT interface CONNECTOR X-941 - 62 pin FPT interface WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 400 (N/G) 2

424 (S/W)

392 (B/W)

399 (N/B)

404 (O/B)

413 (R/G)

396 (G/W)

406 (O/U)

423 (R)

415 (W)

11 12

422B (B) 398 (N)

13 14

422 (S/TQ) 421 (S/R)

401 (N/W)

410 (TQ/W)

395 (G/B)

412 (R/B)

403 (O)

420 (S/G)

X-939EDC17 CONNECTOR 1 X-941 Wire harnesses - Electrical schematic frame 19 (55.100) 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface SP-200 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-941 62 pin FPT interface SP-201 X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface

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Electrical systems - Harnesses and connectors

CONNECTOR X-941 - 62 pin FPT interface WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 21 397 (G/Y) 22

405 (O/TQ)

414 (R/U)

24 25

387 (B)

388 (B/Y)

391 (B)

385 (G/W)

418 (S)

408 (TQ)

31 32 33

394 (G)

411 (R)

402 (N/Y)

36 37

416 (R/Y)

407 (O/W)

39 40

X-939EDC17 CONNECTOR 1 X-941 Wire harnesses - Electrical schematic frame 19 (55.100) 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-949Jumper Engine1-Engine2 X-941 62 pin FPT interface X-949Jumper Engine1-Engine2 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-949Jumper Engine1-Engine2 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface -

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Electrical systems - Harnesses and connectors

CONNECTOR X-941 - 62 pin FPT interface WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 41 393 (B/Y) 42

419 (S/B)

409 (TQ/G)

44 45 46 47 48 49 50 51 52 53 54 55 56 57

365 (R/Y)

366 (R/G)

59 60

377 (R/B)

384 (R)

X-939EDC17 CONNECTOR 1 X-941 Wire harnesses - Electrical schematic frame 19 (55.100) 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-939EDC17 CONNECTOR 1 X-941 62 pin FPT interface X-938Glow plugsX-941 62 pin FPT interface X-938Glow plugs X-941 62 pin FPT interface X-941 62 pin FPT interface X-938Glow plugs X-938Glow plugs X-941 62 pin FPT interface -

84154706

MOIL12TR0510AA

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Electrical systems - Harnesses and connectors

CONNECTOR X-942 - Air Temp intake PIN WIRE NUMBER NUMBER 1 327 (OR) 2

328 (OR/BK)

CONNECTOR X-942 - Air Temp intake CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-937EDC17 CONNECTOR 2 X-942Air Temp intake X-937EDC17 CONNECTOR 2 X-942Air Temp intake

84607243

MOIL12TR0511AA

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Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-943 - Lambda Sonde PIN WIRE NUMBER NUMBER 1 316 (OR) 2

317 (GY)

314 (GN)

4 5

319 (GN/WH) 318 (YE)

315 (BR)

CONNECTOR X-943 - Lambda Sonde CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-937EDC17 CONNECTOR 2 X-943Lambda Sonde X-937EDC17 CONNECTOR 2 X-943Lambda Sonde X-937EDC17 CONNECTOR 2 X-943Lambda Sonde X-943Lambda Sonde SP-064 X-937EDC17 CONNECTOR 2 X-943Lambda Sonde X-937EDC17 CONNECTOR 2 X-943Lambda Sonde

84301132

MOIL12TR0512AA

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Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-945 - Temp Exhaust 2 PIN WIRE NUMBER NUMBER 1 322 (GN/WH) 2

320 (BK/WH)

CONNECTOR X-945 - Temp Exhaust 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-937EDC17 CONNECTOR 2 X-945Temp Exhaust 2 X-937EDC17 CONNECTOR 2 X-945Temp Exhaust 2

87709793

MOIL13TR00061AA

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Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-946 - Temp exhaust 1 PIN WIRE NUMBER NUMBER 1 324 (BR/YE) 2

323 (BR/GN)

CONNECTOR X-946 - Temp exhaust 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-937EDC17 CONNECTOR 2 X-946Temp exhaust 1 X-937EDC17 CONNECTOR 2 X-946Temp exhaust 1

87709793

MOIL13TR00062AA

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Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-947 - Diff pressure sensor CONNECTOR X-947 - Diff pressure sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 329 (YE/BK) 2

330 (YE/BR)

331 (YE)

X-937EDC17 CONNECTOR 2 X-947Diff pressure sensor X-937EDC17 CONNECTOR 2 X-947Diff pressure sensor X-937EDC17 CONNECTOR 2 X-947Diff pressure sensor

87747172

MOIL13TR00063AA

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Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-949 - Jumper Engine1-Engine2 CONNECTOR X-949 - Jumper Engine1-Engine2 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 325 (BK) 387 (B)

326 (BK/WH) 388 (B/Y)

344 (GN/WH) 385 (G/W)

334 (BR/YE) 436 (N/Y)

332 (GY) 678 (S)

333 (BL/RD) 769 (B)

X-937EDC17 CONNECTOR 2 X-949Jumper Engine1-Engine2 X-949Jumper Engine1-Engine2 X-941 62 pin FPT interface X-937EDC17 CONNECTOR 2 X-949Jumper Engine1-Engine2 X-949Jumper Engine1-Engine2 X-941 62 pin FPT interface SP-064 X-949Jumper Engine1-Engine2 X-949Jumper Engine1-Engine2 X-941 62 pin FPT interface X-937EDC17 CONNECTOR 2 X-949Jumper Engine1-Engine2 X-938Glow plugs X-949Jumper Engine1-Engine2 X-937EDC17 CONNECTOR 2 X-949Jumper Engine1-Engine2 X-938Glow plugs X-949Jumper Engine1-Engine2 X-937EDC17 CONNECTOR 2 X-949Jumper Engine1-Engine2 SP-138 X-949Jumper Engine1-Engine2

87691968

MOIL12TR0513AA

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Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 95 CONNECTOR X-950 - Water in fuel PIN WIRE NUMBER NUMBER 1 347 (YE) 2

335 (BK)

345 (OR)

CONNECTOR X-950 - Water in fuel CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-950Water in fuel X-937EDC17 CONNECTOR 2 X-950Water in fuel X-420 ENGINE GROUND X-950Water in fuel SP-031

87709663

MOIL12TR0514AA

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Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

X-951 â&#x20AC;&#x201C; Injector cylinder 1 PIN NUMBER 1 2

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

1.50H 1.50H

X-951_X-954OK

MOIL12TR0515AA

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Electrical systems - Harnesses and connectors

X-952 Injector cylinder 2 PIN NUMBER 1 2

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

1.50H 1.50H

X-951_X-954OK

MOIL13TR00064AA

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Electrical systems - Harnesses and connectors

X-953 Injector cylinder 3 PIN NUMBER 1 2

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

1.50H 1.50H

X-951_X-954OK

MOIL12TR0517AA

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Electrical systems - Harnesses and connectors

X-954 Injector cylinder 4 PIN NUMBER 1 2

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

1.50H 1.50H

X-951_X-954OK

MOIL12TR0518AA

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Electrical systems - Harnesses and connectors

X-955 Glow plugs cylinder 1 PIN NUMBER 1

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

2.50H

X-955_X-958OK

MOIL13TR00065AA

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Electrical systems - Harnesses and connectors

X-956 Glow plugs cylinder 2 PIN NUMBER 1

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

2.50H

X-955_X-958OK

MOIL13TR00066AA

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Electrical systems - Harnesses and connectors

X-957 Glow plugs cylinder 3 PIN NUMBER 1

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

2.50H

X-955_X-958OK

MOIL13TR00067AA

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Electrical systems - Harnesses and connectors

X-958 Glow plugs cylinder 4 PIN NUMBER 1

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

2.50H

X-955_X-958OK

MOIL13TR00068AA

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Electrical systems - Harnesses and connectors

X-959 Oil pressure switch PIN NUMBER 1

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

0.50H

X-959OK

MOIL12TR0519AA

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Wire connectors - Component diagram 96 X-960 Wastegate valve PIN NUMBER 1 2

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

0.75H 0.75H

X-960OK

MOIL12TR0520AA

X-961 Boost pressure PIN NUMBER 1 2 3 4

Wire size 0.50H 0.50H 0.50H 0.50H

X-961OK

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

Electrical systems - Harnesses and connectors

MOIL12TR0521AA

X-962 Segment speed PIN NUMBER 1 2 3

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

0.50H 0.50H 0.50H

X-962OK

MOIL12TR0522AA

X-963 Exhaust gas absolute pressure sensor (P3) PIN NUMBER 1 2 3

Wire size 0.50H 0.50H 0.50H

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

Electrical systems - Harnesses and connectors

X-963OK

MOIL12TR0523AA

X-964 EGR PIN NUMBER 1 2 3 4 5 6

Wire size 0.75H 0.50H

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

0.50H 0.75H 0.50H

X-964OK

X-965 Increment speed Wire size

Cavity No. 1 2 3

0.50H 0.50H 0.50H

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

Electrical systems - Harnesses and connectors

X-965OK

X966 TVA PIN NUMBER 1 2 3 4 5 6

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

0.50H 0.75H 0.50H 0.50H 0.75H

X-966OK

MOIL12TR0524AA

X-967 Rail pressure sensor PIN NUMBER 1 2 3

Wire size 0.50H 0.50H 0.50H

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

Electrical systems - Harnesses and connectors

X-967OK

X-968 Fuel temperature sensor PIN NUMBER 1 2

Wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

0.50H 0.50H

X-968OK

MOIL12TR0525AA

X-969 Coolant temperature sensor PIN NUMBER 1 2

Wire size 0.50H 0.50H

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

Electrical systems - Harnesses and connectors

X-969OK

MOIL12TR0526AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 97 X-970 Fuel metering unit HP pump PIN NUMBER 1 2

wire size

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

0.75H 0.75H

X-970OK

MOIL12TR0527AA

X-971 T3 sensor (EPIQ) PIN NUMBER 1 2

wire size 0.50H 0.50H

X-971OK

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 19 (55.100)

Electrical systems - Harnesses and connectors

MOIL12TR0528AA

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 99 CONNECTOR X-0467 - X-0467 PIN WIRE NUMBER NUMBER 1 1 (C) 2 3 4 5

2 7 5 3

(RG) (N) (AG) (RB)

CONNECTOR X-0467 - X-0467 CIRCUIT REFERENCE X-892Battery Negative Stud X-893Boost Terminal Negative X-024Roof cable connection X-056B X-056Electric fan X-0467 SP-062 X-0467 X-115BImplement Socket J-001

84335033

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ELECTRICAL SCHEMATIC FRAME

Electrical systems - Harnesses and connectors

Fuse and relay box - Static description FUSE BOX AND MAIN RELAY T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE

COMPONENT

SIGN REAR COVER

F-001 F-002 F-003 F-004 F-005 F-006 F-007 F-008 F-009 F-010

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10

F-011 F-012 F-013 F-014 F-015 F-016

F11 F12 F13 F14 F15 F16

F-017 F-018 F-019

F17 F18 F19

F-020

F20

F-022 F-023 F-024 F-025 F-026 F-027 F-028 F-029 F-030 F-031 F-032 F-033 F-035 F-036 F-037 F-039 F-040 F-041 F-042 F-044 K-001 K-002 K-003 K-004 K-005

F22 F23 F24 F25 F26 F27 F28 F29 F30 F31 F32 F33 F35 F36 F37 F39 F40 F21 F34 F38 R1 R2 R3 R4 R5

DESCRIPTION Left fan speed third power [+ 12 V F-058 - 200 A] Power CN1A CCU [+ 12 V F-061 - 10 A] Dipped beam power [+ 12 V F-058 - 200 A] Fuel heating power [+ 12 V F-058 - 200 A] " shuttle" lever and gear change power [+ 12 V 15/54 Key] " C&D" clutch power [+ 12 V 15/54 Key] Socket power [+ 12 V 15/54 Key] Flashing light power [+ 12 V F-058 - 200 A] Electronic lift control power ( EDC) [+ 12 V 15/54 Key] Service control valve power: PTO front, PTO rear, differential lock, engagement 4WD [+ 12 V 15/54 Key] Pressure switch and speed sensor power [+ 12 V 15/54 Key] 3rd remote valve valve splitter power [+ 12 V 15/54 Key] Right fan third speed power [+ 12 V F-058 - 200 A] Brake pedal switch power [+ 12 V 15/54 Key] Full beam power [+ 12 V F-058 - 200 A] Power supply to work light switch, roof relay and A/C compressor relay [+ 12 V K-001] Air Condition control unit power [+ 12 V 15/54 Key] Left fan fourth speed power [+ 12 V F-058 - 200 A] Power supply A-005 to hand brake switch and diagnostic sockets [+ 12 V F-061 - 10 A] Power supply A-005 to brake oil level switch, disconnected brake pedals, engine RPM switches, accelerator pedal [+ 12 V 15/54 Key] Light switching power [+ 12 V 15/54 Key] 7-pole socket power ISO [+ 12 V K-002] Position lights power [+ 12 V K-002] Position lights and backlighting power [+ 12 V K-002] Clutch pedal switch power [+ 12 V 58 Key] Engine control unit power [+ 12 V 15/54 Key] Brake light power [+ 12 V K-001] Electric seat and reverse gear alarm relay power [+ 12 V 15/54 Key] Right fan fourth speed power [+ 12 V F-058 - 200 A] Service socket power [+ 12 V F-058 - 200 A] Starter switch power [+ 12 V F-058 - 200 A] Cigar lighter socket power [+ 12 V F-058 - 200 A] Front wiper power [+ 12 V 15/54 Key] Light switch power [+ 12 V F-058 - 200 A] Socket power 8 A [+ 12 V F-058 - 200 A] Front loader controls power [+ 12 V 15/54 Key] Electronic remote valve power ( EHR ) Trailer brake power [+ 12 V 15/54 Key] Power supply ISOBUS +15 [+ 12 V 15/54 Key] Power supply ISOBUS +30 [+ 12 V F-058 - 200 A] Service switch relay Position lights circuit relay Fuel heater relay Left fan third speed relay Right fan third speed relay 47538922 29/05/2013

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COMPONENT K-006 K-007 K-008 K-009 K-010 K-011 K-012 K-013 K-014 K-015 K-016 K-017 K-018

SIGN REAR COVER R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18

DESCRIPTION Left fan fourth speed relay Right fan fourth speed relay 3rd remote valve splitter relay Backup alarm relay Kisa far rolesi/Low beam relay Uzun far rolesi/High beam relay Low beam headlights switch relay. Full beam headlights switch relay. Front loader relay 1 Front loader relay 2 Front loader relay 3 Italy trailer brake relay Trailer brake relay

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MOIL12TR00158HA

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Electrical systems - Harnesses and connectors

MOIL12TR00161HA

A-003

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Fuse and relay box - Static description FUSE BOX AND MAIN RELAY T5.95 ElectroCommand NA, T5.105 ElectroCommand NA, T5.115 ElectroCommand NA

Frequency of service intervals F-001 F-002 F-003 F-004 F-005 F-006 F-007 F-008 F-009 F-010

SIGN REAR COVER F1 F2 F3 F4 F5 F6 F7 F8 F9 F10

F-011 F-012 F-013 F-014 F-015 F-016

F11 F12 F13 F14 F15 F16

F-017 F-018 F-019

F17 F18 F19

F-020

F20

F-022 F-023 F-024 F-025 F-026 F-027 F-028 F-029 F-030 F-031 F-032 F-033 F-035 F-036 F-037 F-039 F-040 F-041 F-042 F-044 K-001 K-002 K-003 K-004 K-005 K-006

F22 F23 F24 F25 F26 F27 F28 F29 F30 F31 F32 F33 F35 F36 F37 F39 F40 F21 F34 F38 R1 R2 R3 R4 R5 R6

DESCRIPTION Left fan speed third power [+ 12 V F-058 - 200 A] Power CN1A CCU [+ 12 V F-061 - 10 A] Dipped beam power [+ 12 V F-058 - 200 A] Fuel heating power [+ 12 V F-058 - 200 A] " shuttle" lever and gear change power [+ 12 V 15/54 Key] " C&D" clutch power [+ 12 V 15/54 Key] Socket power [+ 12 V 15/54 Key] Flashing light power [+ 12 V F-058 - 200 A] Electronic lift control power ( EDC) [+ 12 V 15/54 Key] Service control valve power: PTO front, PTO rear, differential lock, engagement 4WD [+ 12 V 15/54 Key] Pressure switch and speed sensor power [+ 12 V 15/54 Key] 3rd distributor splitter power [+ 12 V 15/54 Key] Right fan third speed power [+ 12 V F-058 - 200 A] Brake pedal switch power [+ 12 V 15/54 Key] Full beam power [+ 12 V F-058 - 200 A] Power supply to work light switch, roof relay and A/C compressor relay [+ 12 V K-001] Air Condition control unit power [+ 12 V 15/54 Key] Left fan fourth speed power [+ 12 V F-058 - 200 A] Power supply A-005 to hand brake switch and diagnostic sockets [+ 12 V F-061 - 10 A] Power supply A-005 to brake oil level switch, disconnected brake pedals, engine RPM switches, accelerator pedal [+ 12 V 15/54 Key] Light switching power [+ 12 V 15/54 Key] 7-pole socket power ISO [+ 12 V K-002] Position lights power [+ 12 V K-002] Position lights and backlighting power [+ 12 V K-002] Clutch pedal switch power [+ 12 V 58 Key] Engine control unit power [+ 12 V 15/54 Key] Brake light power [+ 12 V K-001] Electric seat and reverse gear alarm relay power [+ 12 V 15/54 Key] Right fan fourth speed power [+ 12 V F-058 - 200 A] Service socket power [+ 12 V F-058 - 200 A] Starter switch power [+ 12 V F-058 - 200 A] Cigar lighter socket power [+ 12 V F-058 - 200 A] Front wiper power [+ 12 V 15/54 Key] Light switch power [+ 12 V F-058 - 200 A] Socket power 8 A [+ 12 V F-058 - 200 A] Front loader controls power [+ 12 V 15/54 Key] Electronic remote valve power ( EHR ) Trailer brake power [+ 12 V 15/54 Key] Power supply ISOBUS +15 [+ 12 V 15/54 Key] Power supply ISOBUS +30 [+ 12 V F-058 - 200 A] Service switch relay Position lights circuit relay Fuel heater relay Left fan third speed relay Right fan third speed relay Left fan fourth speed relay 47538922 29/05/2013

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Electrical systems - Harnesses and connectors

Frequency of service intervals K-007 K-008 K-009 K-010 K-011

SIGN REAR COVER R7 R8 R9 R10 R11

DESCRIPTION Right fan fourth speed relay 3rd distributor splitter relay Backup alarm relay Kisa far rolesi/Low beam relay Uzun far rolesi/High beam relay

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MOIL12TR00159HA

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

MOIL12TR00162HA

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Electrical systems - Harnesses and connectors

Fuse and relay box - Static description FUSE BOX AND RELAY FOR ROOF EQUIPMENT Frequency of SIGN REAR service intervals COVER A-006 X-937, X-939 F-045 F-046 F-047 F-048 F-049 F-050 F-051 F-060 K-025 K-026 K-027 K-028

DESCRIPTION Engine Control Unit ECU Rear wiper power [+ 12 V K-026] Air Condition fan power [+ 12 V K-026] Radio power [+ 12 V K-026] Beacon power [+ 12 V F-058 - 200 A] Rear worklamp power [+ 12 V F-058 - 200 A] Front worklamp power [+ 12 V F-058 - 200 A] +30 radio power [+ 12 V F-058 - 200 A] Spare Air conditioning compressor relay Roof power relay Front working lamp relay Relay rear work lights

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Electrical systems - Harnesses and connectors

MOIL12TR00160HA

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Electrical systems - Harnesses and connectors

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MOIL12TR00163HA

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Wire harnesses - Repair 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

1z0o2004112112

1z0o2004112113

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.

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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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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Wire harnesses - Rewire Harness Wire Replacement 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: 1. Locate the faulty wire using the procedures described in the fault code charts. 2. Disconnect the affected connectors. 3. If fitted carefully roll back the seal between the connector and harness outer covering. 4. 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.

SEZ55CAP9B-17

SEZ55CAP9B-5

5. 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. 6. Join the new wire to the new pins as described in the harness repair kit and install one of the pins into its connector. 7. 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 install the second terminal into its connector block. Replace the connector seal if removed. 8. 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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Wire harnesses - Measure Digital multimeter NOTE: This section is only intended as a general guide to using a digital multimeter. Always refer to the manufactures operators manual for correct operation. A multimeter is an electronic measuring device. The different types of measurement that can be made depend upon the make and model of the multi--meter. Most types of multimeter have the capacity to measure: • Current (A) ac or dc • Resistance (Ω) • Voltage (V) ac or dc • Continuity (Buzz test) More expensive multimeters have other functions, such as the capacity to measure frequency (Hz) and test diodes.

SEZ55CAP9A-50

SEZ55CAP9A-51

SEZ55CAP9A-2

General Operation: Before proceeding with a test, decide on what is going to be measured (Voltage, Current etc.). Rotate the dial until the pointer is within the relevant zone. Within each zone there are different scales. The scale that is selected will represent the maximum value that the multimeter will read. Always select a scale which is greater than the value that you intend to measure. If you are unsure of the value to be measured, always select the highest scale and then reduce the scale once you have an idea of the measured value.

Why are there different scales ? The closer that the scale is to the measured value, the more accurate the reading will be e.g. If measuring the voltage of a battery with the scale set at 200 V, the display may read 12 V. However, if the scale was set to 20 V the display may read a more accurate reading of 12.27 V.

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Measuring Voltage (Volts): Set the range dial to either ac or dc volts. Connect the Black test probe to the ”COM” terminal and the Red test probe to the ”V/Ω” terminal. Place the test probes across the component to be measured with the circuit complete (closed). Read off the display value.

SEZ55CAP9A-52

SEZ55CAP9A-53

SEZ55CAP9A-3

SEZ55CAP9A-54

Measuring Current (Amps): Set the range dial to either ac or dc current. When measuring current up to 2 amps, connect the Red test probe to the ”A” terminal. When measuring current up to 10 A, connect the Red test probe to the 10 A terminal. Always connect the Black test probe to the ”COM” terminal. When taking measurement of current, always break the circuit and connect the multi meter in series with the circuit. Read off the display value.. NOTE: For protection, multimeters are usually fused at 10 A

Measuring Resistance (Ohms): Set the range dial to the desired Q position. Connect the Red test probe to the ”V/Ù” terminal. Connect the Black test probe to the ”COM” terminal. If the resistance being measured is connected in a circuit, then turn off the power to the circuit. Connect the test probes to the measuring point and read off the display value.

Continuity (Buzzer) test: Set the range dial to the ”Buzz” position. Connect the Red test probe to the ”V/Ω” terminal. Connect the Black test probe to the ”COM” terminal. Connect the test probes to the measuring point. In general, if the resistance is less than 50 Ω then the buzzer will sound, indicating continuity.

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NOTE: Buzzers on different multimeters will sound at different ohmic values, depending on the quality of the meter. This can often be misleading, for example when checking a corroded earth point. A poor quality multimeter may buzz at 150 ÎŠ, indicating continuity and no problem. When using a higher quality multimeter for the same test, it would not buzz due to the high resistance. When carrying out such tests, we should always check the value of resistance as well as listening out for the buzz. A good connection gives low resistance. A bad connection gives high resistance.

SEZ55CAP9A-69

SUMMARY: Types of measurement -Voltage (V): Connection to the component with the circuit closed. Current (A): Connection in series with the circuit. Circuit closed. Resistance (ÎŠ): Connection to the component with the circuit open. Continuity (buzzer): Connect the meter to the component with the circuit open. Always check the value of resistance as well!!)

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Wire harnesses - Electrical test Four electrical tests will be required to properly troubleshoot electrical concerns on the vehicle. Each test is described in detail. Ensure that all steps are reviewed and followed when testing. 1. Continuity Test, Short to ground 2. Measuring voltage, shorted to 12 V 3. Resistance test for components 4. Continuity test, Open circuits

SEZ55CAP9B-6

ELECTRICAL TEST PROCEDURE 1: CONTINUITY TEST -- SHORT TO GROUND CONDITIONS FOR PERFORMING TESTS: 1. Power supply OFF, key switch OFF (sometimes battery disconnected or fuse removed, if specified in the procedure). 2. Connectors at each end or ends of circuit disconnected to prevent false readings. 3. Set the meter to measure resistance (Ohms) and measure the resistance in the circuit. Use black lead 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 to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. 4. Determine if measured resistance falls within guidelines specified in the procedure. 3 - 4 ÎŠ 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 100000 ÎŠ indicates that the circuit is free of shorts to ground.

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ELECTRICAL TEST PROCEDURE 2: VOLTAGE MEASUREMENT OR SHORT TO POSITIVE SUPPLY VOLTS CONDITIONS FOR PERFORMING SHORT TO POSITIVE SUPPLY TESTS: 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. 3. Set the meter to measure dc voltage (DC VOLTS) and measure the circuit voltage as illustrated. Use the red meter lead to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. Use black lead 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. 4. Determine if measured voltage falls within guidelines specified in the procedure.

SEZ55CAP9B-1

ELECTRICAL TEST PROCEDURE 3: RESISTANCE TEST FOR ELECTRICAL PARTS CONDITIONS FOR PERFORMING RESISTANCE TEST NOTE: The resistance values shown are valid for a temperature of 20 °C (68.00 °F). With higher or lower tractor temperatures, the relative resistance values shown in the manual should vary accordingly.

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1. Disconnect tractor part by unplugging electrical connectors to expose the part assembly connector for testing. 2. Set electrical meter to measure resistance or Ohms and insert test probes into connector terminals specified in procedure. When checking potentiometers, measure from wiper terminal to each of the other terminals while TURNING THE POT SHAFT. This will ensure no open spots escape detection. When checking rocker or rotary switches, actuate the switch while measuring for opens and shorts. 3. Compare measured values to values specified in the fault code procedures. Allow plus or minus 5 % of range tolerance for all measurements.

SEZ55CAP9B-7

ELECTRICAL TEST PROCEDURE 4: CONTINUITY TEST -- CHECK FOR OPEN CIRCUITS CONDITIONS FOR PERFORMING CONTINUITY TESTS: 1. 1. Key switch OFF (sometimes disconnect battery or remove fuses). 2. Connectors at both ends of the circuit disconnected. All other connectors must be reconnected to perform test. 3. Set the meter to measure resistance (Ohms) and measure the resistance in the circuit as illustrated. Use the red meter lead to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. Use black lead 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. 4. Determine if measured resistance falls within guidelines specified in the procedure. If the resistance is no more than 3 - 4 ÎŠ, the circuit is continuous. More resistance usually indicates dirty or corroded terminals in connectors, and 100000 ÎŠ indicates an open circuit.

SEZ55CAP9B-2

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Index Electrical systems - 55 Harnesses and connectors - 100 Wire harnesses - Electrical schematic frame 01 BATTERY, ALTERNATOR AND POWER SUPPLY UNIT (with and without battery isolator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 T5.95 ElectroCommand NA, T5.105 ElectroCommand NA, T5.115 ElectroCommand NA

Wire harnesses - Electrical schematic frame 02 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Wire harnesses - Electrical schematic frame 03 ELECTRONIC LIFT (EDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Wire harnesses - Electrical schematic frame 04 POWER TAKE OFF, DIFFERENTIAL LOCK, 4 WHEEL DRIVE 48 Wire harnesses - Electrical schematic frame 05 AIR CONDITIONED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Wire harnesses - Electrical schematic frame 06 WORKLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE

Wire harnesses - Electrical schematic frame 06 WORK LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 T5.95 ElectroCommand NA, T5.105 ElectroCommand NA, T5.115 ElectroCommand NA

Wire harnesses - Electrical schematic frame 07 ROAD LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE

Wire harnesses - Electrical schematic frame 07 ROAD LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 T5.95 ElectroCommand NA, T5.105 ElectroCommand NA, T5.115 ElectroCommand NA

Wire harnesses - Electrical schematic frame 08 WINDSCREEN WIPERS AND ROTATING BEACONS . . . . . . . 60 Wire harnesses - Electrical schematic frame 09 SERVICE SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Wire harnesses - Electrical schematic frame 10 BRAKE PEDALS, LICENSE PLATE LIGHT AND 3RD REMOTE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Wire harnesses - Electrical schematic frame 11 CAN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Wire harnesses - Electrical schematic frame 12 INTERNAL ISOBUS LINE TO CAB . . . . . . . . . . . . . . . . . . . . . . . . 68 Wire harnesses - Electrical schematic frame 13 EXTERNAL ISOBUS LINE TO CAB . . . . . . . . . . . . . . . . . . . . . . . 70 Wire harnesses - Electrical schematic frame 14 TRANSMISSION CONTROL 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Wire harnesses - Electrical schematic frame 15 TRANSMISSION CONTROL 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Wire harnesses - Electrical schematic frame 16 INSTRUMENT PANEL CONTROL UNIT 1 . . . . . . . . . . . . . . . . . 76 Wire harnesses - Electrical schematic frame 17 INSTRUMENT PANEL CONTROL UNIT 2 . . . . . . . . . . . . . . . . . 78 Wire harnesses - Electrical schematic frame 18 ENGINE CONTROLS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Wire harnesses - Electrical schematic frame 19 ENGINE CONTROLS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Wire harnesses - Electrical schematic frame 20 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Wire harnesses - Electrical schematic frame 21 ROOF FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Wire harnesses - Electrical schematic frame 22 FLASHER UNIT, LIGHTS CONTROL SWITCH AND RADIO . . 88 Wire harnesses - Electrical schematic frame 23 FRONT-END LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Wire harnesses - Electrical schematic frame 24 ITALIAN TRAILER BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Fuse and relay box - Static description FUSE BOX AND MAIN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE

Fuse and relay box - Static description FUSE BOX AND MAIN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 T5.95 ElectroCommand NA, T5.105 ElectroCommand NA, T5.115 ElectroCommand NA

Fuse and relay box - Static description FUSE BOX AND RELAY FOR ROOF EQUIPMENT . . . . . . . . . . . . . . . . 457 Wire connectors - Component Diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Wire connectors - Component diagram 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

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Wire connectors - Component diagram 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Wire connectors - Component diagram 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Wire connectors - Component diagram 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Wire connectors - Component diagram 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Wire connectors - Component diagram 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Wire connectors - Component diagram 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Wire connectors - Component diagram 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Wire connectors - Component diagram 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Wire connectors - Component diagram 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 Wire connectors - Component diagram 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Wire connectors - Component diagram 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 Wire connectors - Component diagram 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Wire connectors - Component diagram 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Wire connectors - Component diagram 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 Wire connectors - Component diagram 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Wire connectors - Component diagram 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Wire connectors - Component diagram 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 Wire connectors - Component diagram 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Wire connectors - Component diagram 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Wire connectors - Component diagram 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Wire connectors - Component diagram 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 Wire connectors - Component diagram 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Wire connectors - Component diagram 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 Wire connectors - Component diagram 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Wire connectors - Component diagram 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 Wire connectors - Component diagram 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 Wire connectors - Component diagram 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 Wire connectors - Component diagram 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 Wire connectors - Component diagram 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 Wire connectors - Component diagram 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Wire connectors - Component diagram 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309 Wire connectors - Component diagram 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Wire connectors - Component diagram 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Wire connectors - Component diagram 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 Wire connectors - Component diagram 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 Wire connectors - Component diagram 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 Wire connectors - Component diagram 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 Wire connectors - Component diagram 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366 Wire connectors - Component diagram 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 Wire connectors - Component diagram 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 Wire connectors - Component diagram 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372 Wire connectors - Component diagram 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

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Wire connectors - Component diagram 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376 Wire connectors - Component diagram 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382 Wire connectors - Component diagram 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383 Wire connectors - Component diagram 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 Wire connectors - Component diagram 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 Wire connectors - Component diagram 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394 Wire connectors - Component diagram 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401 Wire connectors - Component diagram 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402 Wire connectors - Component diagram 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 Wire connectors - Component diagram 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 Wire connectors - Component diagram 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 Wire connectors - Component diagram 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418 Wire connectors - Component diagram 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 Wire connectors - Component diagram 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438 Wire connectors - Component diagram 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 Wire connectors - Component diagram 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446 Wire harnesses - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Wire harnesses - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Wire harnesses - Electrical schema ADIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Wire harnesses - Electrical schema CCU CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Wire harnesses - Electrical schema index COMPONENTS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Wire harnesses - Electrical schema index DESCRIPTION INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Wire harnesses - Electrical schematic frame 01 BATTERY, ALTERNATOR AND POWER SUPPLY UNIT (with battery isolator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE

Wire harnesses - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468 Wire harnesses - Measure Digital multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465 Wire harnesses - Overview BUS protocol connections and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Wire harnesses - Overview HOW TO USE THE WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wire harnesses - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462 Wire harnesses - Rewire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464 Wire harnesses - Wiring standard COLOR CODE OF THE WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Electrical systems - 55 Engine starting system - 201

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Electrical systems - 55 Engine starting system - 201

TECHNICAL DATA Engine starting system Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine starting system Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Engine starting system Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Electrical systems - Engine starting system

Engine starting system - Torque TORQUE SETTINGS Starter motor and engine block assembly bolts Casing on starter motor/ground wire side Solenoid valve wire nuts Box nuts on starter motor side Solenoid valve retaining bolts

34 N·m (300.93 lb in) 16 N·m (141.61 lb in) 7 N·m (61.96 lb in) 10 N·m (88.51 lb in) 5 N·m (44.25 lb in)

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Electrical systems - Engine starting system

Engine starting system - Exploded view Starter motor components

SEZ55CAP3H-2

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Electrical systems - Engine starting system

(1). (2). (3). (4). (5).

Control side support. Electromagnet Engage Front-Wheel Reduction unit

(6). Armature (7). Field coils and casing (8). Brush Holder (9). Brush plate (10). Armature

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Electrical systems - Engine starting system

Engine starting system - Overview MAIN DATA Starting Motor Power Voltage Weight Pinion: Number of teeth Z module

All models Iskra AZF4251 4.2 kW 12 V 10.5 kg (23.1 lb) 10 3,175

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Electrical systems - Engine starting system

Engine starting system - Disassemble 1.

Lift the bonnet and remove the right plastic guard.

WLAPL4S55C303A

WLAPL4S55C307A

WLAPL4S55C308A

WLAPL4S55C309A

Unscrew the motor retainer screw (1), then disconnect the negative battery cable (3) and the engine ground cable (2) .

ATTENTION: Take care to ensure that the negative battery cable foes not come into contact with the metal parts of the chassis.

Remove the plastic guard (1) retaining screw (2). Then remove the guard

Having removed the bolt, remove the three positive terminals (2): - battery power - power to the engine connector block and maxi fuses - alternator charge cable.

Remove the coil cable (1) from the starter relay.

To reassemble the starter motor, carry out the removal operations in reverse order.

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Electrical systems - Engine starting system

Engine starting system - Install 1.

To reassemble the starter motor, carry out the disassembly operations in reverse order ( Engine starting system - Disassemble (55.201)).

NOTE: Before reassembly, check the armature axial end-float and test the starter motor (without load).

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Electrical systems - Engine starting system

Engine starting system - Disassemble NOTE: refer to the figure in Engine starting system - Exploded view (55.201) 1.

Position the starter motor in a vice with padded jaws.

Disconnect the biggest braided cable that connects the field coils casing with the electromagnet.

Remove the three screws from the front casing and extract the electromagnet. Remember that the plunger remains connected to the control lever.

Remove the electromagnet plunger by raising and releasing it from the control lever.

Remove the two nuts from the rear casing and the two screws that secure the rear cover and the brush plate to the casing. Remove the â&#x20AC;&#x153;Câ&#x20AC;? clamp and the armature shaft end-float adjustment shims, leaving the brush gear on the switch. Remove the fine metal washer from the switch side of the armature.

At this stage of the procedure, check the brushes and commutator. Check that the brushes are not stuck together and, if necessary, clean both the brushes and the respective channels with a cloth soaked in kerosene. Also check that the brushes are not worn. If the minimum length is less than that shown in the technical data, the starter motor will need to be replaced.

NOTE: The brushes cannot be serviced separately. They are welded to their support and will not be changed for the whole operating life of the starter motor. 7.

Extract the motor casing from the armature and the bracket on the control side.

Extract the control lever knuckle pin from the control side of the casing.

Remove the circlip that holds the control unit and the inner plate to the armature shaft, by first removing the circlip retaining collar perpendicularly using a suitably sized piece of piping. Then lever the circlip from the groove.

10.

Extract the armature and control unit.

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Electrical systems - Engine starting system

Engine starting system - Check Checking armature end float 1.

Position the starter motor in a vice with padded jaws and connect a dial gauge to the flange on the control side of the casing. Position the dial gauge pointer on the end of the armature shaft.

Push the armature fully forward and zero-set the dial gauge. Push the armature fully back and note the reading on the instrument.

Readings must fall within the limits specified in the technical information table. If the value is higher, check that armature and brush plate are not worn. Replace worn parts and, if necessary, check the end float again.

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Index Electrical systems - 55 Engine starting system - 201 Engine starting system - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine starting system - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine starting system - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine starting system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine starting system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine starting system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine starting system - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Alternator - 301

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Electrical systems - 55 Alternator - 301

TECHNICAL DATA Alternator General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Alternator Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Alternator Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Tension adjust belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Electrical systems - Alternator

Alternator - General specification Type

Iskra AAK4860 Negative earth 14 V 12000 RPM 120 A 2.75 Ω

Polarity Nominal voltage Maximum Speed Maximum output Energizing circuit resistance

Alternator - Torque Alternator fastening bolts Pulley retaining nut Rectifier attaching screws Brush box and regulator screws Terminal nuts

5.5 N·m (48.68 lb in) 70 N·m (619.55 lb in) 4.0 N·m (35.40 lb in) 2.7 N·m (23.90 lb in) 2.7 N·m (23.90 lb in)

Alternator - Special tools 380001268: Belt tension meter.

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Electrical systems - Alternator

Alternator - Static description DESCRIPTION OF THE ALTERNATOR An Iskra-type 120 A external cooling fan alternator is fitted on all models. Stator winding is ventilated with an air-conducting diaphragm in the support on the rectifier bridge side and peripheral openings in the support on the control side. The alternator, installed on the right-hand side of the engine, is operated by a pulley and a driving belt. Alternators are fitted with a built-in regulator. 1. Alternator speed connection (terminal (W)) not used. 2. Alternator charge indicator connection ( (D+) terminal). 3. Battery connection ( (B+) terminal).

SEZ55CAP4A-2

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Electrical systems - Alternator

Alternator - Component localisation Alternator components

SEZ55CAP4F-2

(1). (2). (3). (4). (5). (6). (7). (8). (9).

Pulley Bearing Cooling fan Front support plate Stator Rotor Rear support plate Rectifier Cover

(10). (11). (12). (13). (14). (15). (16). (17). (18).

Terminals: B+, D+ and W Seals Condensor Rear Bearing Brush Holder Brushes Strip, Rubber Retaining ring Felt gasket

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Electrical systems - Alternator

Alternator - Check SYSTEM TESTING AND TROUBLESHOOTING PRECAUTIONS DURING THE OPERATION To avoid damage to the components of the alternator charging system, the following precautions must be observed: •

DO NOT MAKE OR INTERRUPT any charging circuit connection, including the battery, while the engine is running.

•

NEVER SHORT–CIRCUIT the alternator positive terminal to check if it is working.

•

ALWAYS DISCONNECT battery cables when re-charging the battery on the tractor with a battery charger.

•

ALWAYS CHECK battery polarity when installing a battery or using a supplementary battery to start the engine.

•

DO NOT SHORT–CIRCUIT regulator input/output terminals when the alternator is working.

•

CONNECT POSITIVE TO POSITIVE AND NEGATIVE TO NEGATIVE.

PRELIMINARY CHECKS Before carrying out these electrical tests, carefully inspect the charging system and the electrical system in general. Check continuity in all conductors and connections, making sure they are correctly tightened.

1. CHECK THE BATTERY Check all battery elements with a densimeter. The battery must be at least 70% charged and efficient.

2. CHECK THE DRIVE BELT Inspect the alternator driving belt and pulley, making sure that they are both clean and in good condition, with no traces of oil or grease. Check the alternator driving belt tension regularly.

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Electrical systems - Alternator

Alternator - Tension adjust belt If the belt tension is insufficient, check the belt tensioner as indicated below. 1.

Loosen the screw in the slot of the belt tensioner (3) and that of the alternator pivot (1), the belt tensioner tie-rod / alternator fastening screw (2), then loosen the lock nut of the screw at the end of the belt tensioner (4).

WLAPL4S55C301A

WLAPL4S55C301B

The drive belt is tensioned as follows: 2.

Tighten the screw of the belt tensioner tie-rod to reset the lower slot of the tie-rod, in practice it must be pulled fully, as it is an elastic belt.

Tighten the lock nut of the screw ( (5), 1), tighten the other three screws of the belt tensioner tie-rod ( (1), (2) and (3), fig. 1). Components shown in figure 2: (1)series tractor. Alternator pulley. (2)series tractor. Coolant pump. (3)series tractor. Alternator. (4)series tractor. Fan hub. (5)series tractor. Belt tensioner tie rod.

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Electrical systems - Alternator

Alternator - Remove ATTENTION: Before disconnecting the alternator wires, make sure that the starter key is in the OFF position. 1.

Lift the bonnet and remove the right plastic guard.

WLAPL4S55C303A

WLAPL4S55C304A

WLAPL4S55C305A

WLAPL4S55C306A

Slightly loosen the alternator pivot screw ( (1), 4). Loosen the screws on the tensioning rod and the tie rod lock nut, then completely unscrew the latter, remove the elastic belt (2).

Disconnect the charge indicator cable (1) and the battery charger cable (2).

Unscrew the pivot screw (1) and take out the alternator.

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Electrical systems - Alternator

Alternator - Install 1.

Refit the alternator by following the removal procedure in reverse order Alternator - Remove (55.301).

NOTE: During re-installation, remember to: â&#x20AC;˘ make sure that the negative (ground) battery cable is disconnected from the battery during alternator installation. â&#x20AC;˘ regulate the alternator driving belt as described above.

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Index Electrical systems - 55 Alternator - 301 Alternator - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Alternator - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Alternator - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Alternator - Tension adjust belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Alternator - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Battery - 302

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Electrical systems - 55 Battery - 302

TECHNICAL DATA Battery General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Battery Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Battery Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Electrical systems - Battery

Battery - General specification CHARACTERISTICS Voltage Cold start amperage ( C.C.A) Capacity Number of elements Weight Grounding terminal

All models 12 V 800 A 140 AÂˇh 6 39 kg (86 lb) Negative

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Electrical systems - Battery

Battery - Dynamic description DESCRIPTION AND OPERATION The 140 A·h battery is assembled on all models with cab conditions system and is installed in the compartment under the right steps. The four main functions of a battery are: • To supply a source of electricity for starting, ignition and instrument lighting and functioning. • To control voltage in the electrical system. • To supply electricity when the power required is higher than that produced by the alternator. • To support inactive loads from radio and microprocessor memory. Each element of the battery consists of positive and negative plates, positioned alternatively, one next to the other. Each positive plate is separated from the adjacent negative plate by means of a porous insulating spacer. If one of the positive plates touches a negative plate in the element, the element will short-circuit and be irreversibly damaged. All of the positive plates are welded to a bar and form a positive terminal, whereas all of the negative plates are welded to a similar bar and form a negative terminal. Each positive plate consists of a lead grid with lead peroxide pasted to the grid holes. The negative plates consist of a lead grid with lead sponge pasted to the grid holes. The plates are covered by electrolyte formed by a diluted sulphuric acid solution. The battery casing is made of polypropylene.

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Electrical systems - Battery

Battery - Remove It is housed in the compartment under the right steps. To access the battery, proceed as follows: 1.

Remove the retainer (1), then lift the steps, which will pivot on the pivot screws.

Use the knob (2) to remove the battery compartment cover.

Disconnect the ground lead from the negative battery terminal, place it safely away from the chassis.

Loosen the nut and disconnect the positive battery cable, taking care to ensure it does not come into contact with the battery.

Using the handles, fitted on both ends of the battery, lift and remove the battery from its housing. MOIL13TR00113AA

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Electrical systems - Battery

Battery - Install Applicable to all types of battery 1.

To re-install the battery, reverse the removal procedure ( Battery - Remove (55.302)), with the following precautions: •

Check that the battery is clean, there are no signs of electrolyte leak and the breather covers are completely installed. Spread petrolatum (e.g.: vaseline); do not use traditional lubricants as they favour electrolytic corrosion.

•

Make sure that the battery housing and support are clean without objects (stones, etc.) which could pierce the battery casing.

•

Make sure that the battery terminal polarity is correct and that the terminal connections are suitably (but not excessively) tightened.

•

The radio and the clock will lose their data stored in memory and will need to be reprogrammed. Electronic control units and microprocessors - when installed - will not lose stored data, as electronic stress and transmission control calibration are not involved in this operation.

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Electrical systems - Battery

Battery - Charging On the tractor range only one type of battery is used ( 140 AÂˇh), in this chapter the recharging procedure is described for 140 AÂˇh and 100 AÂˇh batteries (although for the time being this is not used). NOTE: All claims under warranty concerning the batteries must indicate the battery date code.

Batteries type A NOTE: The following batteries are used only in production. 1.

They can be identified by: - The part number hot stamped on the top of the battery casing or given on the label (even though necessarily at times these do not correspond to the numbers used as spares). - The position of the production date code. The date code is on the bottom right-hand side of the positive terminal. Example of date code: 14L 7 044 14 L = Production Plant 7 = Year (2007) 044 = Progressive number SEZ55CAP5A-2

Batteries type B NOTE: The following batteries are used in production and in the spare parts service for changing batteries. They can be identified by: - The part number hot stamped on the top of the battery casing or given on the label (even though necessarily at times these do not correspond to the numbers used as spares). - The position of the production date code. The date code is on the bottom right-hand side of the positive terminal. Example of date code: 7C CW06 7 = Year (2007) C = Month (February) A = December, B = January, C = February, D = March, E = April, F = May, G = June, H = July, J = August, K = September, L = October, M = November. CW06= Production plant

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Index Electrical systems - 55 Battery - 302 Battery - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Battery - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - 55 Electronic modules - 640

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Electrical systems - 55 Electronic modules - 640

FUNCTIONAL DATA Electronic modules Fault code index Calibration U-code listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Electronic module Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE Electronic module View HH MENU ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 View HH MENU OF THE CONTROL PANEL (ZD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 H3 - Configurations and options of the control panel module (ZD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 H4 - View software revision level control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 H5 - Switch operation test control switches (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 H8 - Clear stored calibration information (EEPROM) (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 H9 - Voltmeter diagnostic on control panel (ZD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 HB - Display stored fault codes on control panel (ZD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 View list of electronic lift error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 View engine error codes list (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 View list of transmission error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 View rear PTO error code listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 View list of fourâ&#x2C6;&#x2019;wheel drive error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 View list of differential lock error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 HC - Clear all stored fault codes on control panel (ZD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 HF - View controller hardware information on control panel (ZD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 View HH MENU OF THE TRANSMISSION (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 H1 - Calibration procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 H2 - View stored calibration values by the transmission (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 H3 - Configurations and options of the module (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 H4 - View software revision level of the module (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 H5 - Switch operation test for the module (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 H6 - Vehicle information view on the transmission (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 H7 - Vehicle test modes on the central control unit (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 H8 - Clear stored calibration information (EEPROM) on the central control unit (RI) . . . . . . . . . . . . . . . . 71 H9 - Voltmeter diagnostic of the central control unit (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 47538922 29/05/2013

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HB - Display stored fault codes on the central control unit (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 HC - Clear all stored fault codes on the central control unit (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 HE - Display frequency inputs on the central control unit (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 HF - View controller hardware information central control unit (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 HJ - Electronic hydraulic remote control valve number programming of the central control module (RI) 80

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Electrical systems - Electronic modules

Electronic modules - Fault code index Calibration U-code listing Calibration code U17 - Seat switch not activated U19 - Oil temperature below 10°C, calibration not allowed U20 - Handbrake is not set U21 - ERPM is below 1050, increase throttle U22 - ERPM is above 1350, reduce throttle U23 - Shuttle lever is in neutral, shift lever to forward U26 - Clutch pedal is not up, release clutch pedal U27 - C3 calibration value is too low U29 - C4 calibration value is too low U31 - Wheel speed sensed U32 - C1 calibration value is too low U34 - C2 calibration value is too low U36 - Max allowed clutch calibration value exceeded U37 - Synchroniser potentiometer signal is out of range for the reverse position U38 - Synchroniser potentiometer signal is out of range for the forward position U39 - Synchroniser did not move toward reverse, even at maximum pressure U40 - Synchroniser did not move toward forward, even at maximum pressure U41 - Synchroniser pot signal is out of range for the 4 position U42 - Synchroniser pot signal is out of range for the 5 position U43 - Synchroniser did not move toward 4, even at max pressure U44 - Synchroniser did not move toward 5, even at max pressure U82 - No 12VD: no power for C3 and C4 solenoids U147 - Synchroniser cannot be engaged

Description of Fault Seat switch not activated Oil Temperature below 10 °C (50.00 °F).

Handbrake is not set ERPM is below 1050, increase throttle ERPM is above 1350, reduce throttle Shuttle lever is in neutral, shift it to forward

Clutch pedal is not up, release clutch pedal C3 calibration value is too low C4 calibration value is too low Wheel speed sensed C1 calibration value is too low C2 calibration value is too low Max allowed clutch calibration value exceeded Synchroniser potentiometer signal is out of range for the reverse position

Synchroniser potentiometer signal is out of range for the forward position

Synchroniser did not move toward reverse, even at maximum pressure

Synchroniser did not move toward forward, even at maximum pressure

Synchroniser pot signal is out of range for the 4 position

Synchroniser pot signal is out of range for the 5 position

Synchroniser did not move toward 4, even at max pressure

Synchroniser did not move toward 5, even at max pressure

No 12VD: no power for C3 and C4 solenoids Synchroniser cannot be engaged

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Electrical systems - Electronic modules

Calibration code Description of Fault U148 - Range lever not in Range lever not in the high range position the high range position CL - COLD OIL WARNING: COLD OIL WARNING: displayed between 10 and 60 degrees C displayed below 60 degrees C HOT OIL WARNING: displayed above 105 degrees C CH - HOT OIL WARNING: displayed above 105 degress C

ERROR CODE U17 - SEAT SWITCH NOT ACTIVATED Possible fault modes: 1. Operator is not sitting in the seat 2. Open circuit between the seat switch and the instrument cluster 3. Seat switch faulty 4. 12 V supply to the switch is open circuit NOTE: Use the H5 switch diagnostics of the instrument cluster to detect if the seat switch is connected, if the switch has diagnostics then use the H9 diagnostics ch26.

ERROR CODE U19 - TRANSMISSION OIL TEMPERATURE IS BELOW 10 °C (50.00 °F) Possible fault modes: 1. Transmission oil is very cold 2. Transmission oil temperature sensor open circuit 3. Oil temperature sensor faulty 4. Oil temperature sensor short to ground

ERROR CODE U20 - HANDBRAKE IS NOT SET Possible fault modes: 1. The parking brake is not engaged 2. Open circuit between the parking brake switch and the instrument cluster 3. Parking brake switch faulty 4. 12 V supply to the switch is open circuit NOTE: Use the H5 switch diagnostics of the instrument cluster to detect if the parking brake switch is connected.

ERROR CODE U21 - ERPM IS BELOW 1050, INCREASE THROTTLE Possible fault modes: 1. Operator has not set the correct engine speed 2. Open circuit between the engine speed sensor and the engine controller 3. CAN circuit faulty NOTE: Use the HE menu ch. 3 to see if the engine speed is being detected.

ERROR CODE U22 - ERPM IS ABOVE 1350, REDUCE THROTTLE Possible fault modes: 1. Operator has not set the correct engine speed

ERROR CODE U23 - SHUTTLE LEVER IS IN NEUTRAL, SHIFT LEVER TO FORWARD Possible fault modes: 47538922 29/05/2013

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Electrical systems - Electronic modules

1. Operator has not selected forward on the shuttle lever 2. Open circuit between the shuttle lever and the central control unit ( CCU) 3. 12 V supply to the shuttle lever is open circuit NOTE: Use the H5 switch diagnostics of the RI transmission control unit to detect if the switch is connected.

ERROR CODE U26 - CLUTCH PEDAL IS NOT UP, RELEASE CLUTCH PEDAL Possible fault modes: 1. Operator has not released the clutch pedal 2. The clutch pedal potentiometer linkage is sticking or faulty NOTE: Use the H9 in the transmission control unit to see if the clutch input is OK.

ERROR CODE U27 - C3 CALIBRATION VALUE IS TOO LOW Possible fault modes: 1. RPM dropped too soon 2. Clutch pressure is not being controlled properly 3. Engine speed adjusted whilst completing calibration

ERROR CODE U29 - C4 CALIBRATION VALUE IS TOO LOW Possible fault modes: 1. RPM dropped too soon 2. Clutch pressure is not being controlled properly 3. Engine speed adjusted whilst completing calibration

ERROR CODE U31 - WHEEL SPEED SENSED Possible fault modes: 1. The parking brake is not engaged 2. Brakes not working NOTE: If the brakes are okay, move the vehicle slightly forward and repeat the calibration. NOTE: Use the H5 switch diagnostics of the instrument cluster to detect if the parking brake switch is connected.

ERROR CODE U32 - C1 CALIBRATION VALUE IS TOO LOW Possible fault modes: 1. RPM dropped too soon 2. Clutch pressure is not being controlled properly 3. Engine speed adjusted whilst completing calibration

ERROR CODE U34 - C2 CALIBRATION VALUE IS TOO LOW Possible fault modes: 1. RPM dropped too soon 2. Clutch pressure is not being controlled properly 3. Engine speed adjusted whilst completing calibration

ERROR CODE U36 - MAX ALLOWED CLUTCH CALIBRATION VALUE EXCEEDED Possible fault modes: 1. The speed does not drop 47538922 29/05/2013

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Electrical systems - Electronic modules

2. No or low oil pressure to the clutch 3. Mechanical failure breaking the torque path

ERROR CODE U37 - SYNCHRONISER POTENTIOMETER SIGNAL IS OUT OF RANGE FOR THE REVERSE POSITION Possible fault modes: 1. Synchroniser potentiometer has been painted through production 2. Synchroniser potentiometer connector has been damaged 3. Synchroniser assembly is very tight / sticky NOTE: Use the voltmeter to check the syncro potentiometer signal. If OK then repeat calibration to free up syncro.

ERROR CODE U38 - SYNCHRONISER POTENTIOMETER SIGNAL IS OUT OF RANGE FOR THE FORWARD POSITION Possible fault modes: 1. Synchroniser potentiometer has been painted through production 2. Synchroniser potentiometer connector has been damaged 3. Synchroniser assembly is very tight / sticky NOTE: Use the voltmeter to check the synchroniser potentiometer signal. If OK then repeat calibration to free up syncro.

ERROR CODE U39 - SYNCHRONISER DID NOT MOVE TOWARD REVERSE, EVEN AT MAXIMUM PRESSURE Possible fault modes: 1. The forward and reverse solenoid connectors need to be swapped 2. The reverse solenoid is faulty 3. No oil pressure to shift the synchroniser 4. Synchroniser potentiometer has been painted through production 5. Synchroniser potentiometer connector has been damaged NOTE: Remove the transmission top cover and watch the synchroniser movement to help detect failure or use H9 and look at the potentiometer signal with a voltmeter.

ERROR CODE U40 - SYNCHRONISER DID NOT MOVE TOWARD FORWARD, EVEN AT MAXIMUM PRESSURE Possible fault modes: 1. The forward and reverse solenoid connectors need to be swapped 2. The forward solenoid is faulty 3. No oil pressure to shift the synchroniser 4. Synchroniser potentiometer has been painted through production 5. Synchroniser potentiometer connector has been damaged NOTE: Remove the transmission top cover and watch the synchroniser movement to help detect failure or use H9 and look at the potentiometer signal with a voltmeter.

ERROR CODE U41 - SYNCHRONISER POT SIGNAL IS OUT OF RANGE FOR THE 4 POSITION Possible fault modes: 1. Synchroniser potentiometer has been painted through production 2. Synchroniser potentiometer connector has been damaged 3. Synchroniser assembly is very tight / sticky 47538922 29/05/2013

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Electrical systems - Electronic modules

NOTE: Use the voltmeter to check the synchroniser potentiometer signal. If OK then repeat calibration to free up synchroniser.

ERROR CODE U42 - SYNCHRONISER POT SIGNAL IS OUT OF RANGE FOR THE 5 POSITION Possible fault modes: 1. Synchroniser potentiometer has been painted through production 2. Synchroniser potentiometer connector has been damaged 3. Synchroniser assembly is very tight / sticky NOTE: Use the voltmeter to check the syncroniser potentiometer signal. If OK then repeat calibration to free up synchroniser.

ERROR CODE U43 - SYNCHRONISER DID NOT MOVE TOWARD 4, EVEN AT MAX PRESSURE Possible fault modes: 1. The 1-4 and 5-8 solenoid connectors need to be swapped 2. The 1-4 solenoid is faulty 3. No oil pressure to shift the synchroniser 4. Synchroniser potentiometer has been painted through production 5. Synchroniser potentiometer connector has been damaged NOTE: Remove the transmission top cover and watch the synchroniser movement to help detect failure or use H9 and look at the potentiometer signal with a voltmeter.

ERROR CODE U44 - SYNCHRONISER DID NOT MOVE TOWARD 5, EVEN AT MAX PRESSURE Possible fault modes: 1. The 1-4 and 5-8 solenoid connectors need to be swapped 2. The 5-8 solenoid is faulty 3. No oil pressure to shift the synchroniser 4. Synchroniser potentiometer has been painted through production 5. Synchroniser potentiometer connector has been damaged NOTE: Remove the transmission top cover and watch the synchroniser movement to help detect failure or use H9 and look at the potentiometer signal with a voltmeter.

ERROR CODE U82 - NO 12VD: NO POWER FOR C3 AND C4 SOLENOIDS Possible fault modes: 1. Clutch pedal not released 2. Wiring fault to X-200 pin 8 (YE/BK) 3. Faulty central control unit CCU

ERROR CODE U147 - SYNCHRONISER CANNOT BE ENGAGED Possible fault modes: 1. Faulty control solenoid 2. No oil pressure to the synchroniser 3. Faulty synchroniser

ERROR CODE U148 - RANGE LEVER NOT IN THE HIGH RANGE POSITION

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Electrical systems - Electronic modules

Possible fault modes: 1. Range lever is not in the high range position

ERROR CODE CL- COLD OIL WARNING: DISPLAYED BELOW 60 DEGREES C Possible fault modes: 1. Transmission oil is cold - between 10°C to 60°C NOTE: If “CL” (10°C to 60°C) or “CH” (above 105°C) is displayed, after 4 seconds the display will return to oil temperature and the tractor may be operated to obtain the correct transmission oil temperature. If it is not practical to wait for the oil temperature to change, press either the up or down shift buttons while “CL” or “CH” is being displayed. The display will then show “Syn” and calibration can proceed.

ERROR CODE CH- HOT OIL WARNING: DISPLAYED ABOVE 105 DEGREES C Possible fault modes: 1. Transmission oil is hot - above 105°C NOTE: If “CL” (10°C to 60°C) or “CH” (above 105°C) is displayed, after 4 seconds the display will return to oil temperature and the tractor may be operated to obtain the correct transmission oil temperature. If it is not practical to wait for the oil temperature to change, press either the up or down shift buttons while “CL” or “CH” is being displayed. The display will then show “Syn” and calibration can proceed.

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Electrical systems - Electronic modules

Electronic module - Static description ELECTRONIC CONTROL UNITS The electronic control units (1) are the ”black boxes” that provide control on many of the functions of the tractor. These functions may vary according to the options that are fitted on the tractor. Inside these ”black boxes” there is a processor, the ”thinking part” of the control unit, and inside some of them there is one or more memories, which may allow the control unit to store calibration values, the configuration of the vehicle (which optional tools or devices have been installed) and the error codes. A processor has a series of pins, which are electrical contacts (see 2). There are three main types of pin: for the inputs of the signals, for the outputs and for the processor supply. The processor, the memories and the link between them form the hardware of the control unit, its ”physical” part. Then some software is needed, to handle the communication between the processor and the memories and to manage the various signals going into and out of the processor. The software is designed to operate in a different way for every control unit, and is called functional code. To provide a continuous control on components, the processor continuously scans all the inputs in a time-- sharing mode, with a cycle lasting 0.01 s. This means that all the components controlled by the processor are checked one by one, and that every component is checked 100 times per second. Control units are often blamed as responsible for most of the problems of modern tractors, while they are for certain among the most protected parts of the tractor. In fact, the pins of the control units are protected against spikes (high pulses) of current, and the signals are filtered by the hardware and by the software in input and in output to give the best handling of information.

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SEZ55CAP9A-64

SEZ55CAP9A-65

Electrical systems - Electronic modules

Electronic module - View HH MENU ACCESS Turn the ignition switch ( (2) , 2 ) onto A (OFF) and connect the implement 380000843 (2) to the relevant diagnostics socket (1) , after taking off the protective cap.

WLAPL4S55C1001A

WLAPL4S55C1002A

WLAPL4S55C1003A

WLAPL4S55C1004A

Turn the ignition switch (2) onto (B) , the information monitor will display HH MENU (see image 2 ).

Using the buttons ( (1) , 2 ) located in the guard under the steering wheel navigate through the menus HH . Press the first button (1) on the side: HOME A to exit the program (when possible), ENTER (B) to confirm the program you want to go to with the settings button (2) , by pressing it on the side: UP (A) , for setting the digital number, DOWN (B) for the blink number to set, it is possible to pass from one control unit to the other, from one option to the other.

The display is subdivided into 5 parts, the parts used by the HH programs are: 1) displaying all the information on calibration, channels, and diagnostics switches and sensors and for the gearbox control unit RI error codes and settings. 2) displaying the icons of the various levels of the programs, and for the control unit of the dashboard ZD , error codes and settings information. error codes, settings choices

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Electrical systems - Electronic modules

Pressing the button ( (2) , 3 ) on side (A) or (B) shifts from the control unit of the dashboard ZD to the control unit of the transmission RI or OA (optional), with the button ( (1) , 3 ) on side (B) you confirm the control unit to which you want to go; the display will show the image (A) , 6 . The arrows at the sides mean that by pressing the button ( (2) , 3 to the right or left, you can move between the various screens.

MOIL13TR00410AA

MOIL13TR00411AA

The menu of the selected control unit (A) appears on the information monitor. If the control unit responds to the menu access ADIC message negatively (B) , the attention sign will appear, in this case you need to turn the switch ( (2) , 2 ) to (A) (OFF) and repeat the MENU HH access procedure after checking the supply and connection of the relevant control unit are correct. (A) . Correct access (B) . Module responds incorrectly

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Electrical systems - Electronic modules

Electronic module - View HH MENU OF THE CONTROL PANEL (ZD) H3 − OPTIONS H4 − SOFTWARE REVISION LEVEL H5 − CONTROL SWITCHES DIAGNOSTICS H8 − DELETE DATA SAVED IN MEMORY H9 − VOLTMETER FUNCTIONS HB − SAVED FAULTS DISPLAY HC − DELETION OF SAVED FAULTS HF − HARDWARE VERSION

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Electrical systems - Electronic modules

Electronic module - H3 - Configurations and options of the control panel module (ZD) Access the HH MENU ZD as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. â&#x2C6;&#x2019; Select the MENU H3 with the UP or DOWN buttons (2), press the ENTER button (1) to access the HH menu program.

WLAPL4S55C1007A

MOIL13TR00412AA

MOIL13TR00413AA

Select the MENU H3 options with the UP and DOWN buttons ( (2) , 1 ) and press the ENTER button ( (1) , 1) to access modification of the chosen option.

After making the modifications to the options with the UP and DOWN buttons ( (2) , 1 ); press the UP or DOWN button ( (2) , 1), for a period of 1 s an acoustic signal will be emitted for saving, press the HOME button of the instrument cluster to come back out of the option. After seeing this, without making any changes to the options of the chosen program press the HOME button ( (1) , 1) to return to the HH menu where it is possible to move between the various options. - With the ENTER buttons ( (1) , 1) you can choose from among the options for error code management. â&#x2C6;&#x2019; The display will show: LIVE = shows all the error codes; FACTORY = (factory settings) displays all error codes until 6 min has passed without any error codes, then will automatically go in error code reduction ( ECR): default setting. ECR = shows only the critical error codes. - Use the UP or DOWN button ( (2) , 1) to move the arrow onto the desired choice.

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Electrical systems - Electronic modules

- With the ENTER buttons ( (1) , 1) you can choose from among the options for engine shutdown management. − The display will show: YES 1 = The engine shall always be requested to shutdown if at least one of the following conditions shall be detected: a) Engine oil pressure too low ; b) Engine coolant temperature too high ; c) Driveline oil temperature too high when the operator is not present and the tractor is not moving ; d) Driveline oil pressure too low when the operator is not present and the tractor is not moving ; YES 2 = the Engine shall be requested to shutdown if at least one of the following condition is detected: a) Engine oil pressure too low when the operator is not present and the tractor is not moving ; b) Engine coolant temperature too high when the operator is not present and the tractor is not moving ; c) Driveline oil temperature too high when the operator is not present and the tractor is not moving ; d) Driveline oil pressure too low when the operator is not present and the tractor is not moving . NO = The engine shall never be requested to shutdown. - Use the UP or DOWN button ( (2) , 1) to move the arrow onto the desired choice.

MOIL13TR00414AA

MOIL13TR00415AA

MOIL13TR00416AA

- With the ENTER buttons ( (1) , 1) you can choose from between the two options for electronic lift management. − The display will show: YES = The electronic lift is enabled (factory setting). NO = The electronic lift is disabled. - Use the UP or DOWN button ( (2) 1) to move the arrow onto the desired choice. NOTE: The software on this machine is common to other machines where there is the mechanical lift option.

- With the ENTER buttons ( (1) , 1) you can choose from between the two options for fuel heater management. − The display will show: YES = If the machine has a heater (factory setting). NO = If it does not have a heater. - Use the UP or DOWN button ( (2) , 1) to move the arrow onto the desired choice.

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Electrical systems - Electronic modules

− With the ENTER buttons ( (1) , 1 ) you can choose PTO over-revving management from between the two options. − The display will show: YES = To enable the option (factory setting). NO = If you want to disable the option. - Use the UP or DOWN button ( (2) , 1) to move the arrow onto the desired choice. NOTE: On selecting the NO option the machine does not signal exceeding the PTO speed.

MOIL13TR00417AA

MOIL13TR00418AA

MOIL13TR00419AA

- With the ENTER buttons ( (1) , 1) you can choose between the two options for managing the information to display on the monitor ( (2) , figure 4 Electronic module - View HH MENU ACCESS (55.640) , at the bottom on the left, the one shown in the image 8 ). − The display will show: YES = To enable the display multi-option. NO = If you want to reduce the display information (factory setting). - Use the UP or DOWN button ( (2) , 1) to move the arrow onto the desired choice. NOTE: Choosing the YES option displays: Odometer Area worked Area per hour (working speed) Battery voltage. Air Brake Pressure (if Air Brake H3 option = YES) Electro hydraulic remotes ( EHR)(if available) Choosing the NO option displays: Battery voltage Air Brake Pressure (if Air Brake H3 option = YES) - With the ENTER buttons ( (1) , 1) you can choose from between the two options for buzzer volume management. − The display will show: YES (with cab)= buzzer volume is reduced (default setting). NO (less cab) = buzzer volume is increased. - Use the UP or DOWN button ( (2) , 1) to move the arrow onto the desired choice.

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Electrical systems - Electronic modules

- With the ENTER buttons ( (1) , 1) you can choose whether to enable the idle speed reduction logic. − The display will show: YES = To enable the logic (factory setting). NO = To disable it. - Use the UP or DOWN button ( (2) , 1) to move the arrow onto the desired choice. NOTE: The logic element intervenes by automatically decreasing the engine rpm, to save fuel, when there are the following conditions: Operator not present Transmission in neutral or in park condition Machine speed equal to 0 km/h (0.0 mph) Hand throttle and pedal throttle both in the idle speed position Foot pedal released No engine loads Constant engine speed ( CRPM ) off or not applicable PTO not engaged Electro hydraulic remotes ( EHR) in neutral Electronic draft control ( EDC) not rising no low battery (Battery Voltage > 11000 mV ) Air-conditioning system off If these conditions are broken, the transmission oil temperature decrease under a value of 38 °C (100.4 °F) or the engine oil temperature goes down the value of 58 °C (136.4 °F), the engine idle speed will return to its preset values. If the system remains in this stage for a long time, there will be a temporary increase in engine speed in order to avoid problems with the exhaust gas treatment system.

MOIL13TR00420AA

MOIL13TR00423AA

MOIL13TR00422AA

- With the ENTER buttons ( (1) , 1) you can choose from between the two options for air brake presence. − The display will show: YES = present. NO = not present (default setting). - Use the UP or DOWN button ( (2) , 1) to move the arrow onto the desired choice.

- With the ENTER buttons ( (1) , 1) you can choose from between the two options to use the front PTO option to include the front PTO speed visualization. − The display will show: YES = enabled. NO = disabled (default setting). - Use the UP or DOWN button ( (2) , 1) to move the arrow onto the desired choice.

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Electrical systems - Electronic modules

- With the ENTER buttons ( (1) , 1) you can choose from between the two options used to enable or disable the Constant (revolutions per minute) CRPM logic. â&#x2C6;&#x2019; The display will show: YES = enabled. NO = disabled (default setting). - Use the UP or DOWN button ( (2) , 1) to move the arrow onto the desired choice.

MOIL13TR00421AA

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Electrical systems - Electronic modules

Electronic module - H4 - View software revision level control panel Access the HH MENU ZD as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. â&#x2C6;&#x2019; Select the MENU H4 with the UP or DOWN buttons (2), press the ENTER button (1) to access the MENU H4 program.

â&#x2C6;&#x2019; The top portion of the display will show the identification numbers of the control unit software release in sequence: 1469 - Application software for ZD module (1476 for RI module and 1017 for OA module if present). The second and third set of 4 digits displayed define the release version of the application software: 01 - Main release. 00 - Secondary release. 01 - Development project. 02 - Development iteration. The software version displayed by H4 may not match the software version indicated on the label of the module if the new software has been downloaded to the module after manufacture. Four dashes will indicate the end of the visualization.

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WLAPL4S55C1007A

MOIL13TR00424AA

Electrical systems - Electronic modules

Electronic module - H5 - Switch operation test control switches (control panel) NOTE: This menu is used to check for transitions on switch for diagnostic purposes. On analog inputs, a “transition” means that a fixed threshold was crossed. The display shows a “d_ _” plus a number that indicates which circuit had a transition and beeps momentarily whenever a transition occurs. The number displayed indicates which circuit had a transition. This menu also checks for disagreement of the shuttle lever forward, neutral and reverse switches. The neutral switch is not tested separately with its own “d” number, because the operator has no way to cause a transition on the neutral switch without simultaneously causing a transition on the forward or reverse switch. If the shuttle lever is shifted with the clutch pedal up, the neutral switch will also cause a transition on 12V , which is used to test the clutch pedal switch. Because of the interaction of these switches: The forward and reverse switches must be tested with the clutch pedal down; The clutch pedal switch must be tested with the shuttle lever in gear, not in neutral; If the key switch is turned to the “crank” position with the shuttle lever in neutral and the clutch pedal down (normal starting procedure) a switch disagreement error can occur (only in diagnostic mode). When a low-high transition occurs on the clutch pedal switch (pedal moving up), the clutch pedal calibration values are checked and the switch adjustment is checked. To ensure proper check-out: 1. enter switch diagnostics mode with the clutch pedal fully up; 2. depress the clutch fully and pause at least one second; 3. slowly release the clutch pedal (two second min. from down to up). Access the HH MENU ZD as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H5 with the UP or DOWN buttons (2), press the ENTER button (1) to access the MENU H5 program.

WLAPL4S55C1007A

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Electrical systems - Electronic modules

− The top portion of the display will show the code number of the switch that has been operated. The display will show a “ d_ _ ” . On detection of a switch transition, the display will show “ d ” followed by the switch number for which the transition was detected: if multiple switch transitions are detected then the display will show each circuit in turn. The display will also show “ d0 ” if a transition occurs on a switch input which is undefined for the module.

MOIL13TR00425AA

WLAPL4S55C1021A

- At the end of the test procedure the only operation that remains is to turn the key (1) onto position (A) (OFF).

d11 d60 d61 d66

Code

Switch code S-055 S-037 S-001 S-048

d67 d68 d70 d71 d72 d73 d103 d110 d111 d112 d115

S-074 S-073 A-007 A-007 S-045 S-042 S-044 S-039 A-007 A-007 S-071

d116

S-071

d121 d122

S-002 S-072

d123

S-071

d131 d132 d133 d135

S-039 S-040 S-040 S-015

Component name Handbrake Switch Foot Throttle Switch Battery Isolator switch High beam headlights warning light input Sidelights Brake pedals not latched switch Left direction indicator input Right direction indicator input Trailer brake Brake fluid level switch Engine intake air filter Home-enter switch ENTER input Indicator Trailer 1 Indicator Trailer 2 CRPM (constant revolutions per minute) Setting + CRPM (constant revolutions per minute) Setting Cranking Detection CRPM (constant revolutions per minute) On & Off CRPM (constant revolutions per minute) 1 & 2 Home-enter switch HOME input Up-down switch UP input Up-down switch DOWN input Work lights switch

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ECU pin X-460 X-450 X-460 X-460

8 5 2 6

X-460 X-450 X-460 X-460 X-460 X-460 X-460 X-450 X-450 X-450 X-450

19 9 9 10 12 18 3 20 17 18 15

X-450 - 16 X-460 - 17 X-460 - 26 X-460 - 7 X-450 X-450 X-450 X-460

21 23 22 23

Electrical systems - Electronic modules

Electronic module - H8 - Clear stored calibration information (EEPROM) (control panel) Access the HH MENU ZD as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H8 with the UP or DOWN buttons (2), press the ENTER button (1) to access the MENU H8 program.

WLAPL4S55C1007A

WLAPL4S55C1021A

MOIL13TR00426AA

MOIL13TR00427AA

− Select the desired submenu of MENU H8 with the UP or DOWN buttons (2), press the ENTER button (1) to access the desired program.

− After selecting " CLEAR NET CONFIG " if you want to delete the control panel memory, the display will show " 05 ". − If you want to delete it, press and hold down the DOWN button ( (2) , 1 ). − The display will run a countdown from 5 to 1 and will then show " EE ", you can now release the button. NOTE: If the button is released during the countdown, deletion will not take place.

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Electrical systems - Electronic modules

- The only permissible operation is to turn the key (1) onto (A) (OFF). - Once you have turned the key (B) (ON), the on-board panel is able to re-run machine auto-configuration, recognizing the modules with which it is connected on the CAN line.

WLAPL4S55C1021A

MOIL13TR00428AA

- After selecting " CLEAR SETTINGS " if you want to cancel all the values set in the set-up and the fault codes, the display will show " 05 ". â&#x2C6;&#x2019; If you want to delete them, press and hold down the DOWN button ( (2) , 1 ). â&#x2C6;&#x2019; The display will run a countdown and will then show " EE ", you can now release the button. NOTE: If the button is released during the countdown, deletion will not take place. - The only permissible operation is to turn the key ( (1) , 5) onto (A) (OFF) to allow the reset values to be stored. With the exception of Error Codes Management, also for ADIC none of the H3 settings can be deleted by an H8 action: the only way to change one of the these settings is through an H3 . NOTE: The following table describes the values canceled with this option in detail. PARAMETER Implement width Maintenance Keys Audible Feedback Error codes Unit of measurement Error Code Management Area Worked Odometer Dimming

Factory values (default) 0 OFF (no warning) YES No error Metric Factory 0 0 50%

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Electrical systems - Electronic modules

Electronic module - H9 - Voltmeter diagnostic on control panel (ZD) Access the HH MENU ZD as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H9 with the UP or DOWN buttons (2), press the ENTER button (1) to access the MENU H9 program.

WLAPL4S55C1007A

WLAPL4S55C1004A

MOIL13TR00430AA

- The top portion of the display ( (1) , 2 ) will show " ch__ ", using the UP or DOWN button ( (2) , 1 ) to choose the channel of the component to test. After displaying the channel to test " ch25 " the display will show the value read by the control unit ”1077”. - At the end of the test you can only turn the key in the A position (OFF), other actions are not possible. NOTE: You can enter this mode with the engine running. The box below shows the components you can test.

Description ECU pin* Standard value 5 volt power supply X-460 - 1 4500 - 5500 mV #1 6 5 volt power supply X-460 - 14 4500 - 5500 mV #2 8 Foot throttle X-450 -5 250 - 4500 mV S-037 10 + 12 V power supply X-460 - 20 9000 - 16000 mV 24 B-033 Air Brake Pressure X-377 -5 376 - 4536 mV 25 B-012 Fuel level X-450 - 2 850 - 3670 mV 26 X-450 - 1 1430 - 2870 mV S-041 Operator present switch 90 B-011 Hand Throttle 1 X-450 - 8 200 - 4800 mV 199 Alternator not X-460 - 13 9800 - 16000 mV G-002 charging * - Refer to the ("System diagram" Wire harnesses - Electrical schema ADIC CONTROL UNIT (55.100) ) of the advance digital instrument cluster ADIC 5

Comp. code

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Electrical systems - Electronic modules

Electronic module - HB - Display stored fault codes on control panel (ZD) Access the HH MENU ZD as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU HB with the UP or DOWN buttons (2), press the ENTER button (1) to access the MENU HB program.

WLAPL4S55C1007A

MOIL13TR00431AA

- The display, showing the programs, please see the figure, will show the fault codes recorded by the control unit. − # = 3127 Besides the fault number, the display will show in sequence: FIRST = number of hours when the fault occurred the first time; LAST = number of hours when the fault occurred the last time; COUNT = number of times the fault has occurred. − You can select the various faults by pressing the UP and DOWN button ( (2) , 1). -If no errors are present in the selected subsystem, “- - - -” will be displayed and you cannot select subsystem; otherwise, if an error is present for the selected subsystem, “F” is displayed in the top area of the screen. - After viewing the codes, press the ENTER button ( (1) , 1 ) to return to the HH menu where you can move between the various options.

List of fault codes displayed by the ADIC ZD control unit Description of fault Supply voltage at 5 V too high Supply voltage at 5 V too low Cranking sensing line shorted to + 12 V Cranking sensing line shorted to + 12 V Fuel tank level sender open circuit or short to voltage Fuel tank level sender short to ground Operator presence switch on for longer than 25 hours Pneumatic brake pressure sensor shorted to + 12 V or sensor not 14061 connected Seat switch signal short to voltage or open circuit 14093 Seat switch signal short to ground 14094 Pneumatic brake pressure sensor detected but not configured 14100 Battery isolator switch on for longer than 30 s after turning the key onto 14200 power 14900 No transmission module on the line CAN Engine module missing 14901 TECU (tractor engine control module) module missing 14908 NOTE: Errors 14015 and 14016 can be healed only after a key off-on transition. Error code 14015 14016 14021 14022 14051 14052 14058

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E.C.R. (*) NO NO NO NO YES YES NO NO NO NO NO NO NO NO NO

Electrical systems - Electronic modules

E.C.R. (*) Description of fault Error code (*) Enter the HH programs of the control panel, select the H3 program, enter the ECR , then select the options: LIVE − show only severe codes, FACTORY − show all codes for 6 minutes of power then pass to “ ECR ”. With option ECR selected, the word: YES - means that the code will not be shown on the display but only kept in memory, NO - means the code will not be shown on the display.

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Electrical systems - Electronic modules

Electronic module - View list of electronic lift error codes Error code 1002 1003 1004 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 1033 1049 1053 1054 1063 1064 1065 1066 1067 1068 1070

Description of fault Radar signal not present Speed sensor signal not present Speed sensor signal too High Slip control potentiometer signal too low Slip control potentiometer signal too high Raise / work switch failure Both ext. sw. operated same time Height limit pot signal too low Height limit pot signal too high Drop rate pot signal too low Drop rate pot signal too high R/H load sensing pin signal too low R/H load sensing pin signal too high L/H load sensing pin signal too low L/H load sensing pin signal too high Both load sensing pin disconnected Load sensing pin voltage too low Load sensing pin voltage too high Sensitivity control potentiometer signal too low Sensitivity control potentiometer signal too high Control panel disconnected Perform the hydraulic lift calibration procedure Position control potentiometer control voltage too low Position control potentiometer control voltage too high Lift arm position sensing control voltage low Lift arm position sensing control voltage high Hydraulic control valve disconnected Break in the ground circuit Chassis harness disconnected Draft control potentiometer control voltage high Draft control potentiometer control voltage low Wheel speed sensor open or short circuit Controller 5 V reference shorted to positive voltage Controller 5 V reference shorted to ground EDC hydraulic valve lower solenoid valve open circuit EDC hydraulic valve raise solenoid valve open circuit EDC hydraulic valve lower solenoid valve short circuit EDC hydraulic valve raise solenoid valve short circuit EDC spool valve supply voltage low Height limit calibration error Hydraulic ram configuration not set

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Electrical systems - Electronic modules

Electronic module - View engine error codes list (ECU) The following symbol will be displayed by the instrument cluster when engine error codes are detected CODE 3001 3002 3003 3007 3008 3010 3011 3015 3016 3019 3024 3025 3027 3037 3038 3051 3052 3059 3063 3071 3079 3083 3088 3089 3090 3091 3093 3096 3102 3104 3105 3106 3107 3108 3112 3126 3127 3137 3139 3140 3141 3146 3157 3158 3166 3167 3168 3169

+ ERROR CODE DESCRIPTION Foot Throttle Sensor - Signal Not Plausible Foot Throttle Sensor - Signal Above Range Max Foot Throttle Sensor - Signal Below Range Min Coolant Temperature Sensor – Signal Above Range Max Coolant Temperature Sensor – Signal Below Range Min Air Intake Temperature Sensor – Signal Above Range Max Air Intake Temperature Sensor – Signal Above Range Min Fuel Temperature Signal – Signal Above Range Max Fuel Temperature Signal – Signal Below Range Min Boost Pressure Sensor – Signal Above Range Max Atmospheric Pressure Sensor – Signal Above Range Max Atmospheric Pressure Sensor – Signal Below Range Min Oil pressure sensor: Defect fault check for plausibility from digital sensor Boost Pressure Sensor – Signal Low “CRPM ON & OFF” and “CRPM 1 & 2” buttons error Battery Voltage to ECU too High Battery Voltage to ECU too Low “ ECU After run was Interrupted F5C : Main Relay: DFC for stuck main relay error” Cylinder1 – Injector Cable Short circuit (High Side to Ground) Cylinder3 – Injector Cable Short circuit (High Side to Ground) Cylinder2 – Injector Cable Short circuit (High Side to Ground) Cylinder4 – Injector Cable Short circuit (High Side to Ground) Crankshaft Sensor – No Signal Crankshaft Sensor – Invalid Signal Camshaft Sensor – No Signal Camshaft Sensor – Invalid Signal Offset Between Camshaft and Crankshaft – Outside Boundaries ECU Bus Off on Vehicle CAN Rail Pressure Sensor CP3 – Signal Below Range Min Rail Pressure Relief Valve – Open Rail Pressure Relief Valve – Pressure Shock Requested Pressure Relief Valve – pressure relief valve is open” Metering Unit – Short circuit to Battery Metering Unit – Short circuit to Ground Rail Pressure Sensor CP3 – Signal Above Range Max Hand Throttle - Channel 1 Signal Above Range Max Hand Throttle - Channel 1 Signal Below Range Min Metering Unit – Open Load Metering Unit Signal Range Check – Signal Too High Metering Unit Signal Range Check – Signal Too Low “Fuel Flow Setpoint Too Low Fuel Metering Unit: leakage is detected based on fuel quantity balance (better description)” Water Detected In Fuel ECU Not Detected on CANbus or The engine data set registration information was not available from the engine within the time required Invalid ECU Checksum (The engine data set installed does not match the dataset registered for this machine. Register the new data set if the data set has just been updated) Fuel Filter Heater Relay – Short circuit to Battery Fuel Filter Heater Relay – Short circuit to Ground Fuel Filter Heater Relay – Open Load Fuel Filter Heater Relay – Signal Not Plausible 47538922 29/05/2013

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Electrical systems - Electronic modules

The following symbol will be displayed by the instrument cluster when engine error codes are detected CODE 3176 3179 3180 3188 3192 3196 3200 3210 3218 3230 3235 3236 3237 3238 3239 3240 3241 3242 3243 3244 3245 3252 3253 3255 3256 3258 3259 3260 3261 3262 3265 3266 3283 3285 3293 3301 3305 3309 3334 3335 3338 3339 3350 3358 3361 3362 3368

+ ERROR CODE DESCRIPTION “Setpoint of Metering Unit Not Plausible in Overrun Fuel Metering Unit: set point of metering unit in overrun mode not plausible” Timeout of CAN Message BC2EDC2 Timeout of CAN Message VCM2EDC Injector Cylinder1 Warning – Open Load Injector Cylinder2 Warning – Open Load Injector Cylinder3 Warning – Open Load Injector Cylinder4 Warning – Open Load Bank1 – General Short circuit on Injection Cable Bank2 – General Short circuit on Injection Cable Injection Processor ( CY33X ) Error – SPI Communication Failure Number of Injection Limited – by Charge Balance Number of Injection Limited – by Quantity Balance Number of Injection Limited – by Software ECU Internal SPI Communication Error – CJ940 ECU EEPROM – Read Operation Failure ECU EEPROM – Write Operation Failure ECU EEPROM – Default Value Used ECU (Locked) Recovery Occurred “ ECU Recovery which is suppressed F5C : ECU internal: Visibility of Software Resets in DSM ” ECU Recovery (Visible) – Recovery Occurred ECU Processor – Watchdog Not Plausible Controller Watchdog – SPI Communication Failure ADC Monitoring – Reference Voltage Too High ADC Monitoring – Test Impulse Error ADC Monitoring – Queue Error “High Side Power – Short circuit to Battery ( ECU Power stages: Starter relay HS power stage output short circuit to battery)” “High Side Power – Short circuit to Ground ( ECU Power stages: Starter relay HS power stage output short circuit to ground)” Low Side Power – Open Load Low Side Power – Short circuit to Battery of Excess Temperature Low Side Power – Short circuit to ground Overrun Monitoring – Injection Time too long Redundant Engine Speed in Overrun Monitoring – Speed Signal Not Plausible Sensor Supply Voltage 2 – High Sensor Supply Voltage 3 – High “Fuel Metering Unit: maximum positive deviation of rail pressure exceeded C10 & C13 1ST P342: Cylinder 1 injector mechanical response fault (replace injector)” Fuel System: maximum negative rail pressure deviation with metering unit on lower limit is exceeded Fuel System: minimum rail pressure exceeded Fuel System: maximum rail pressure exceeded Timeout of CAN message TSC1-PE Torque (When Active) Timeout of CAN message TSC1-PE Torque (When Inactive) Timeout of CAN message TSC1-VE Speed (When Inactive) Timeout of CAN message TSC1-VE Speed (When Active) Terminal 50 – Always On CAN Transmit Timeout ECU EEPROM – General Error Torque to Quantity Map – Not Plausible Info: Torque Limitation due to OBD Performance Limiter by Legislation 47538922 29/05/2013

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Electrical systems - Electronic modules

The following symbol will be displayed by the instrument cluster when engine error codes are detected CODE 3374 3375 3377 3402 3403 3405 3406 3408 3409 3410 3411 3414 3415 3416 3417 3418 3419 3420 3421 3422 3423 3424 3425 3426 3427 3428 3429 3430 3431 3432 3433 3434 3435 3517 3518 3616 3648 3650 3651 3652 3655 3656 3657 3663 3664 3665 3666 3667 3668 3669

+ ERROR CODE DESCRIPTION Injection Quantity Adjustment failure – Invalid EEPROM Adjustment Value Checksum “ CRPM Setting +” and “ CRPM Setting -“ buttons error CRPM switches present but function not enabled Rail pressure sensor: maximum rail pressure exceeded ECU Power stages: Starter relay HS power stage over temperature ECU Power stages: Open load temperature error on the Turbocharger PWM output power stage ECU Power stages: Over temperature error on the Turbocharger PWM output power stage Lambda sensor: Oxygen concentration implausibly high Oil pressure switch: oil pressure too low (at engine running) Permanent governor deviation for valve Permanent governor deviation for valve Array of DFC s for short circuit in i+1th Glow Plug Array of DFC s for short circuit in i+1th Glow Plug Array of DFC s for short circuit in i+1th Glow Plug Array of DFC s for short circuit in i+1th Glow Plug ECU Power stages: SCB error on the Turbocharger PWM output power stage ECU Power stages: SCG error on the Turbocharger PWM output power stage CAN Bus Received frames: DFC of Auxiliary Engine Shutdown Switch Message Fuel filter clogged sensor: voltage above max value Fuel filter clogged sensor: voltage below min value Fuel filter clogged sensor: unplausible value Fuel filter clogged Turbocharger: Over boost deviation at P2 too high in Pressure charger regulator Level 1 of PFlt Overloaded Diesel particulate filter ( DPF ): Signal range check flow resistance of the particulate filter – low ( DPF REMOVAL) Diesel Particulate filter Pressure sensor: not plausibility error Diesel Particulate filter Pressure sensor: hoseline plausibility error EGR Inducement less severe derating level EGR Inducement most severe derating level EGR Inducement warning DPF Inducement less severe derating level DPF Inducement most severe derating level DPF Inducement warning Ambient Air Temperature Sensor failure (of Humidity Sensor if installed) – Signal too high Ambient Air Temperature Sensor failure (of Humidity Sensor if installed) – Signal too low Torque limitation due to turbo charger protection Turbocharger: P2 pressure errors in PCR – Pressure deviation too high Battery voltage: SRC high for battery voltage sensor Battery voltage: SRC low for battery voltage sensor CAN Bus : Bus off of CAN node A Torque limitation, Engine protection: General report of the event of torque limitations Torque limitation, Engine protection: Torque limitation caused by particulate filter CAN Bus Received frames: Timeout Error of CAN -Receive-Frame CM1BC EGR command saturation over higher threshold EGR command saturation over lower threshold Permanent governor deviation for valve Permanent governor deviation for valve Open load error for power stage Over temperature error for H-bridge Short circuit to battery on Out1 error for H-bridge

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Electrical systems - Electronic modules

The following symbol will be displayed by the instrument cluster when engine error codes are detected CODE 3670 3671 3672 3673 3674 3675 3676 3677 3680 3688 3689 3691 3692 3693 3694 3699 3702 3703 3704 3705 3706 3707 3708 3709 3710 3711 3712 3713 3714 3715 3716 3720 3721 3722 3723 3724 3725 3727 3728 3735 3736 3737 3738 3739 3740 3741 3742 3743 3744

+ ERROR CODE DESCRIPTION Short circuit to battery on Out2 error for H-bridge Short circuit to ground on Out1 error for H-bridge Short circuit to ground on Out2 error for H-bridge Short circuit over load error for H-bridge Under voltage error for H-bridge DFC for long time valve drift at closed position DFC for valve position sensor voltage SRC high DFC for valve position sensor voltage SRC low Injection cut off: Injection cut off demand ( ICO ) for shut off coordinator Water sensor in the fuel filter: WIF Sensor Check is failed DFC for faulty diagnostic data transmission or protocol error No load error for Low Voltage System Over temperature error on ECU power stage for Glow plug Low Voltage System Short circuit to battery error for Low Voltage System Short circuit to ground error for Low Voltage System EEPROM : Error in EEPROM block EEP Data1 SD correction cannot be calculated Injection control: Detection of Failed Engine Start Injection control: check of minimum rail pressure Injector Adjustment programming: check of missing injector adjustment value programming Injector Adjustment programming: check of missing injector adjustment value programming Injector Adjustment programming: check of missing injector adjustment value programming Lambda sensor: Open circuit at the lambda sensor Nernst cell pin Lambda sensor: open circuit at the lambda sensor pump current pin â&#x20AC;&#x201C; IP (lambda = 1 detection) Lambda sensor: Open circuit at the lambda sensor Virtual ground pin Lambda sensor: Fault to indicate Dynamics of the sensor signal too small Lambda sensor: SCB error of the LSU Heater Power stage Lambda sensor: SCG error of the LSU Heater Power stage Lambda sensor: Open Load error of the LSU Heater Power stage Lambda sensor: Fault code to indicate SRC High error for O2 calibration Lambda sensor: Fault code to indicate SRC Low error for O2 calibration Lambda sensor: O2 value above the max threshold Lambda sensor: low battery voltage at the SPI chip Lambda sensor: Fault check to indicate SPI chip error of lambda sensor Lambda sensor: LSU sensor temperature Ri exceeds the maximum limit Lambda sensor: LSU sensor temperature Ri is below the minimum limit Lambda sensor: short to battery at IA, IP, UN, VG Lambda sensor: short to ground at IA, IP, UN, VG Info: Low oil viscosity Info: Too low oil viscosity Fuel Metering Unit: over temperature of device driver of metering unit Lambda sensor: O2 concentration is outside the predefined window during Heater coupling detection Lambda sensor: Over temperature error of the LSU Heater Power stage Analog Digital Converter ( ADC ): Diagnostic fault check to report multiple error while checking the complete ROM -memory Power stages, Injector: Loss of synchronization sending bytes to the MM from CPU Power stages, Injector: DFC to set a torque limitation once an error is detected before MoCSOP 's error reaction is set Power stages, Injector: Wrong set response time Power stages, Injector: Too many SPI errors during MoCSOP execution Power stages, Injector: Diagnostic fault check to report the error in under voltage monitoring Power stages, Injector: Diagnostic fault check to report the error in overvoltage monitoring 47538922 29/05/2013

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Electrical systems - Electronic modules

The following symbol will be displayed by the instrument cluster when engine error codes are detected CODE 3745 3746 3747 3748 3750 3751 3752 3753 3754 3755 3756 3757 3758 3759 3760 3761 3762 3763 3764 3766 3767 3768 3769 3770 3773 3786 3787 3789 3790 3791 3794 3795 3796 3797 3798 3799 3800 3801 3802 3803 3808

+ ERROR CODE DESCRIPTION Power stages, Injector: Diagnostic fault check to report that WDA is not working correct Power stages, Injector: OS timeout in the shut off path test. Failure setting the alarm task period Power stages, Injector: Diagnostic fault check to report that the positive test failed Power stages, Injector: Diagnostic fault check to report the timeout in the shut off path test Injection control: Error in the plausibility of the injection energizing time Injection control: Error in the plausibility of the start of energizing angles Zero Fuel Calibration ( ZFC ): Error in the plausibility of the energizing times of the zero fuel quantity calibration Level 2 Monitoring: Diagnostic fault check to report the error due to injection quantity correction Level 2 Monitoring: Diagnostic fault check to report the plausibility error in rail pressure monitoring Level 2 Monitoring: Diagnostic fault check to report the error due to torque comparison Level 2 Monitoring: Diagnosis fault check to report the demand for normal mode due to an error in the PoI2 quantity Level 2 Monitoring: Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI2 shut-off Level 2 Monitoring: Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI3 efficiency factor Level 2 Monitoring: Diagnosis of curr path limitation forced by ECU monitoring level 2 Level 2 Monitoring: Diagnosis air path limitation due to a functional control unit monitoring forced by ECU monitoring level 2 Level 2 Monitoring: Diagnosis quantity path limitation due to a functional control unit monitoring (level 2) Level 2 Monitoring: Reported Overvoltage of Supply Level 2 Monitoring: Reported Under Voltage of Supply Main Relay: Early opening defect of main relay Diesel Particulate filter Pressure sensor: Fault check for the pressure sensor plausibility ECU internal: Diagnostic fault check to report ' WDA active' due to errors in query/response communication ECU internal: Diagnostic fault check to report ' ABE active' due to under voltage detection ECU internal: Diagnostic fault check to report ' ABE active' due to overvoltage detection ECU internal: Diagnostic fault check to report ' WDA/ABE active' due to unknown reason Turbocharger: Under boost detected in Pressure charger regulator Diesel particulate filter ( DPF ): Signal range check flow resistance of the particulate filter â&#x20AC;&#x201C; high Diesel particulate filter ( DPF ): Signal range check flow resistance of the particulate filter â&#x20AC;&#x201C; very high To check if regeneration duration exceeds maximum allowed duration Diesel particulate filter ( DPF ): Signal range check flow resistance of the particulate filter â&#x20AC;&#x201C; max Diagnostic fault check for SRC high in Flow Resistance Intake air pressure sensor: Plausibility Check for air pressure at the upstream of intake valve sensor Intake air pressure sensor: Plausibility Check for air pressure at the upstream of intake valve sensor Diesel Particulate filter Pressure sensor: DFC to indicate hose line error Diesel Particulate filter Pressure sensor: SRC High for PFlt differential pressure sensor Diesel Particulate filter Pressure sensor: SRC low for PFlt differential pressure sensor Pressure Relief valve: pressure relief valve is forced to open, perform pressure shock Pressure Relief valve: Quantity balance check if a successful PRV opening is ensured Turbine upstream pressure sensor: SRC High for Turbine upstream pressure sensor Turbine upstream pressure sensor: SRC Low for Turbine upstream pressure sensor ECU internal: Error on R2S2 module (Low-Level Chip driver for the Power stage-Chips) Fuel Metering Unit: set point of metering unit in idle mode not plausible

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Electrical systems - Electronic modules

The following symbol will be displayed by the instrument cluster when engine error codes are detected CODE 3810 3811 3812 3813 3814 3818 3819 3820 3821 3822 3823 3824 3825 3826 3827 3830 3831 3834 3835 3838 3839 3840 3841 3842 3843 3844 3845 3846 3847 3848 3849 3850 3851 3852 3870 3899 3900 3906 3910 3915 3916

+ ERROR CODE DESCRIPTION Fuel pressure Sensor: Rail pressure raw value is intermittent ECU Sensor Supply Monitor: ECU internal: Error Sensor supplies 1 Physical Range Check high for ECU temperature sensor Physical Range Check low for ECU temperature sensor ECU temperature sensor: SPI Error ECU temperature sensor ( LM71 ) Open load error for power stage Over current error for H-bridge Over temperature error for H-bridge Short circuit to battery on Out1 error for H-bridge Short circuit to battery on Out2 error for H-bridge Short circuit to ground on Out1 error for H-bridge Short circuit to ground on Out2 error for H-bridge Short circuit over load error for H-bridge Temperature dependent over current error for H-bridge Under voltage error for H-bridge DFC for valve position sensor physical SRC high DFC for valve position sensor physical SRC low ECU Power stages: Throttle valve actuator power stage: SRC High ECU Power stages: Throttle valve actuator power stage: SRC Low OxiCat upstream temperature sensor: Diagnostic fault check for SRC high in Oxidation Catalyst upstream temperature OxiCat upstream temperature sensor: Diagnostic fault check for SRC low in Oxidation Catalyst upstream temperature Diesel Particulate filter upstream temperature sensor: Diagnostic fault check for SRC high Diesel Particulate filter upstream temperature sensor: Diagnostic fault check for SRC low Turbine upstream temperature sensor: SRC High for turbine upstream temperature sensor Turbine upstream temperature sensor: SRC low for turbine upstream temperature sensor Zero Fuel Calibration by Lambda ( ZFL ): DFC reporting error state on comparing energizing time to Max value injector 1 Zero Fuel Calibration by Lambda ( ZFL ): DFC reporting error state on comparing energizing time to Max value injector 2 Zero Fuel Calibration by Lambda ( ZFL ): DFC reporting error state on comparing energizing time to Max value injector 3 Zero Fuel Calibration by Lambda ( ZFL ): DFC reporting error state on comparing energizing time to Max value injector 4 Zero Fuel Calibration by Lambda ( ZFL ): DFC reporting error state on comparing energizing time to Min value injector 1 Zero Fuel Calibration by Lambda ( ZFL ): DFC reporting error state on comparing energizing time to Min value injector 2 Zero Fuel Calibration by Lambda ( ZFL ): DFC reporting error state on comparing energizing time to Min value injector 3 Zero Fuel Calibration by Lambda ( ZFL ): DFC reporting error state on comparing energizing time to Min value injector 4 Lambda sensor: The maximum allowed time for blow out is exceeded Timeout for BC2EDC1 Info: Engine temperature exceeded pre-warn level Info: Engine temperature exceeded warn level Injector: Number of injections is limited by quantity balance of high pressure pump Fuel metering unit: Error check for loose contact between metering unit ( MeUn ) and ECU Pressure Relief Valve: Averaged rail pressure is outside the expected range with open PRV Pressure Relief Valve: Open time of PRV for wear out monitoring had exceeded maximum value

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Electrical systems - Electronic modules

Electronic module - View list of transmission error codes Error code 2001 2005 2006 2011 2012 2013 2016 2024 2026 2027 2037 2038 2039 2040 2041 2042 2043 2044 2045 2047 2048 2049 2050 2051 2052 2053 2054 2055 2056 2057 2059 2061 2062 2063 2064 2065 2066 2067 2068 2070 2071 2072 2073 2081 2082 2083 2084 2085 2086 2087 2088 2089 2090

Description of fault Shuttle too fast Creeper engage fault Radar no signal fault Clutch pedal potentiometer signal too low Clutch pedal potentiometer signal too high Upshift and downshift switches ON error Creeper solenoid error At least one synchroniser require calibration Engine speed - too high Engine speed - too low Clutch pedal switch open circuit Clutch 4 solenoid - short to 12 V Clutch 4 solenoid - open circuit Clutch 3 solenoid - short to 12 V 12V Clutch 3 solenoid - open circuit Clutch 2 solenoid - short to 12 V Clutch 2 solenoid - open circuit Clutch 1 solenoid - short to 12 V Clutch 1 solenoid - open circuit Clutch pedal switch set too high Clutch pedal switch set too low Wheel speed sensor - short to ground or open circuit Wheel speed sensor - short to 12 V Oil temperature sensor open circuit Oil temperature sensor short circuit Reference voltage 5 V too high Reference voltage 5 V too low Wheel speed sensor - no signal Low Range switch open circuit Low Range switch open circuit Shuttle Lever switch. disagreement Forward/reverse synchroniser potentiometer signal too high Forward/reverse synchroniser potentiometer signal too low Forward synchroniser did not engage Reverse synchroniser did not engage Forward synchroniser solenoid - open circuit Reverse synchroniser solenoid - open circuit Forward synchroniser solenoid - short to 12 V Reverse synchroniser solenoid - short to + 12 V Shuttle lever forward switch - voltage too high Shuttle lever forward switch - voltage too low Shuttle lever reverse switch - voltage too high Shuttle lever reverse switch - voltage too low 4/5 range synchroniser potentiometer - signal high 4/5 range synchroniser potentiometer - signal low 1-4 range synchroniser engaged error 5-8 range synchroniser engaged error 1-4 range synchroniser solenoid - open circuit 5-8 range synchroniser solenoid - open circuit 1-4 range synchroniser solenoid - short to 12 V 5-8 range synchroniser solenoid - short to 12 V Engine rpm not valid ADIC absent on CAN 47538922 29/05/2013

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Electrical systems - Electronic modules

Error code 2091 2092 2095 2096 2110 2111 2434 2435 2436 2437 2501 2502

Description of fault Clutch 3 not calibrated Clutch 4 not calibrated Clutch 1 not calibrated Clutch 2 not calibrated Signal from the shuttle lever neutral switch high Signal from the shuttle lever neutral switch low Parklock switch input low Parklock switch input high Parklock configuration error Parklock disagreement Oil pressure sensor - open circuit or short to ground Oil pressure sensor - short circuit to + 5 V or VBat

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Electrical systems - Electronic modules

Electronic module - View rear PTO error code listing Error code 5001 5005 5008 5027 5033 5034 5035 5037 5043 5044 5045 5046 5047 5098 5099

Description of fault Rear PTO brake solenoid error Rear PTO brake switch error Rear PTO clutch solenoid - open circuit error Rear PTO speed sensor - open circuit error Rear PTO cab normally closed error Rear PTO fender switch - open circuit / short to ground Rear PTO fender switch - input short to 12 V Rear PTO cab normally open error Rear PTO fender switch stuck on error Rear PTO speed sensor - short to ground Ground speed PTO switch open/short to ground Ground speed PTO switch short to 12 V Ground speed PTO configuration error Rear PTO fender switch option not enabled Rear PTO Auto PTO not enabled

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Electrical systems - Electronic modules

Electronic module - View list of fourâ&#x2C6;&#x2019;wheel drive error codes Error code 6020 6023

Description of fault FWD command switch fault Four-wheel drive solenoid open circuit or short to ground

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Electrical systems - Electronic modules

Electronic module - View list of differential lock error codes Error code 7014 7017

Description of fault Differential lock command switch error - Switch disconnected Differential lock solenoid open circuit or short to ground

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Electrical systems - Electronic modules

Electronic module - HC - Clear all stored fault codes on control panel (ZD) Access the HH MENU ZD as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU HC with the UP or DOWN buttons (2), press the ENTER button (1) to access the MENU HC program.

WLAPL4S55C1007A

MOIL13TR00432AA

WLAPL4S55C1021A

- The display will show " CLEAR ERRORS " and the top portion of the display will show " F CL ". − If you want to delete, press and hold down the DOWN button ( (2) , 1 ). − The display will run a countdown and will then show the letters " EE ", you can now release the DOWN button. NOTE: If the button is released during the countdown, deletion will not take place.

- The only permissible operation is to turn the key (1) onto (A) (OFF).

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Electrical systems - Electronic modules

Electronic module - HF - View controller hardware information on control panel (ZD) Access the HH MENU ZD as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU HF with the UP or DOWN buttons (2), press the ENTER button (1) to access the MENU HF program.

WLAPL4S55C1007A

MOIL13TR00433AA

− The display will show the identification numbers of the control unit hardware release in sequence: 0808 − Hardware module identification. 00.00.00.00 − Hardware module release identification. 000.000.002.263 − Serial number (printed on the control unit label). − At the end of the procedure, auto kick out to HF , from here it is possible to move through all the menus HH .

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Electrical systems - Electronic modules

Electronic module - View HH MENU OF THE TRANSMISSION (RI) H1 − CALIBRATIONS PROCEDURES H2 − VIEW CALIBRATION VALUES H3 − CONFIGURATIONS AND OPTIONS H4 − SOFTWARE REVISION LEVEL H5 − SWITCHES DIAGNOSTICS H6 − VEHICLE INFORMATION VIEW H7 − VEHICLE TEST H8 − DELETE DATA SAVED IN MEMORY H9 − VOLTMETER DIAGNOSTICS HB − SAVED FAULTS DISPLAY HC − DELETION OF SAVED FAULTS HE − FREQUENCY INPUTS HF − HARDWARE VERSION INFORMATIONS HJ − EHR (electrohidraulic remotes unit) VALVE NUMBER PROGRAMMING

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Electrical systems - Electronic modules

Electronic module - H1 - Calibration procedures NOTE: The H1 diagnostic menu is used to perform calibrations of the various tractor systems. Procedures described in following sections are required when either a new control module has been fitted or if the previous calibration has been erased using the “ H8 ” procedure. If, while in calibration, an anomalous condition is detected, it is shown on the display with its error code on alarm lamp; if the wrong condition is relative to the calibration, then its “ U‟ code is displayed on upper LCD.

Error codes NOTE: If the Faults Detection Logic reads a fault condition, the code will flash on the information monitor. In this manner, the fault condition can be displayed whilst in HH mode. During calibration, certain faults may be masked.

SEZ55CAP10A-30

NOTICE: Park the tractor on level ground, away from obstacles (in case of unexpected tractor movement). Engage the handbrake, switch off all electrical switches and the air conditioning system, if on. Set the Shuttle control lever in neutral, the hydraulic lift lower arms down, the supplementary spool valve control levers in neutral and switch off the engine. Put safety wedges under the front and rear wheels. Unless otherwise specified, the levers: − Shuttle control; − gear control; − range gear control; − creeper unit control; are to be understood as being in the NEUTRAL position. If a number preceded by “ U‟ is displayed at any time during the calibration procedure, it is a standard error code. Before doing the calibration it is necessary to remedy the trouble. Start the engine and access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H1 with the UP or DOWN arrow buttons (2), then press the ENTER button (1) to access the MENU H1 program.

WLAPL4S55C1007A

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Shortcut: press and hold the upshift or the downshift switch (2) or (3) of the gear lever (1) , while starting the engine.

WLAPL4S55C1032A

− Select the function of the MENU H1 with the UP or DOWN buttons ( (2) , 1 ).

CLUTCH CALIBRATION TRANSMISSION Press the ENTER button (1) to access the transmission function of MENU H1. − Upon entering the calibration mode, “ CAL ” will be shown on the display, ad above, for a few seconds, then the transmission oil temperature (in degrees Celsius) will be displayed. − To calibrate the clutches the operator must be seated in the driving seat. − Put the shuttle lever into forward, the range lever into the high position and release the clutch pedal. Set the hand throttle to the minimum position. NOTE: The clutches can also be calibrated without the tool 380000843 , simply proceed in the following manner. NOTE: Pressing the upshift or downshift switch display will show the transmission oil temperature status. If the start-up procedure was incorrect, or if the oil is at the incorrect temperature, a “ U” code will be displayed (see U-code listing). − If “ CL ” ( 10 - 60 °C (50.0 - 140 °F) ) or “ CH ” (above 105 °C (221.0 °F) ) is displayed, after 4 s the display will return to oil temperature and the tractor may be operated to obtain the correct transmission oil temperature. If it is not practical to wait for the oil temperature to change, press either the up or down shift buttons while “ CL ” or “ CH ” is being displayed. The display will then show “ Syn ” and calibration can proceed. − If the oil temperature is within the correct range for calibration, the display will show “ Syn ” and calibration can proceed. The transmission is now ready for calibration. There are two methods of calibrating the GPS transmission: the entire sequence can be automated or each item can be calibrated manually.

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Electrical systems - Electronic modules

Automatic calibration: − When the display is showing “ Syn ” (see 4 ), with the hand throttle put the engine between 1100 - 1300 RPM, press and release the range shift switch to start the automatic calibration procedure. − In turn, the synchronisers and the clutches will be calibrated. − When the procedure is complete the display will show “ End” (see 5 ). NOTE: If an error occurs while in this auto mode, the sequence is stopped and the relevant code displayed.

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MOIL13TR00869AA

MOIL13TR00870AA

Electrical systems - Electronic modules

Manual calibration: NOTE: The transmission output speed, seat switch, handbrake switch and clutch pedal position are constantly monitored. Calibration cannot proceed unless the tractor is stationary and the clutch pedal released. Use the upshift button on the hand controller to select “ Syn_ ” step. To calibrate the synchronisers press and hold the downshift button while the display is showing “ Syn_ ”. − The engine has to be set nearly to 1200 RPM. − Synchronisers calibration procedure is initialised when the display show “ Syn1 ” (Forward and Reverse synchronizers range position check). − Keeping the downshift button pressed, the display will then change to show “ Syn2 ” while calibrating pressure for the reverse synchroniser, “ Syn3 ” while calibrating the forward synchroniser, then “ Syn4 ” while the 1-4 synchroniser is calibrated and eventually “ Syn5 ” for 5-8 synchroniser. − On completion of the synchroniser calibration the display will show ' End ' and the engine speed will be set back to idle. The downshift button can then be released. The display will change to show “ C1 ” in preparation for the calibration of clutch 1. Use the upshift button on the hand controller to select “ C_ ”. To calibrate a clutch press and hold the downshift button while the display is showing “ C1 ”, “ C2 ”, “ C3 ” or “ C4 ”. 1. The engine speed will automatically be set to 1200 RPM. 2. The display will show the solenoid current value during the procedure. 3. On completion of the clutch calibration procedure the display will show the clutch number followed by “ End ”, the engine speed will be set back to idle. The downshift button can then be released. The display will then change to show the next clutch in the sequence to be calibrated. 4. Repeat steps 1 to 3 to calibrate each clutch in turn.

MOIL13TR00869AA

MOIL13TR00871AA

WLAPL4S55C1031A

After calibrating all the clutches turn the switch (1) to A (OFF) for at least 2 s to store the calibrations values.

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Electrical systems - Electronic modules

Calibration error code Code U17 U19 U20 U21 U22 U23 U26 U27 U29 U31 U32 U34 U36 U37 U38 U39 U40 U41 U42 U43 U44 U82 U147 U148 CL CH

Description Seat switch not activated Oil temperature < 10 °C (50.0 °F) , calibration is not possible Handbrake not applied ERPM (engine rpm) is below 1050, increase throttle ERPM (engine rpm) is above 1350, reduce throttle Control lever Power Shuttle in neutral, shift it to forward Power for the panel C3 calibration value is too low C4 calibration value is too low Wheel speed sensed C1 calibration value is too low C2 calibration value is too low Max allowed clutch calibration value exceeded Synchroniser potentiometer signal is out of range for the reverse position Synchroniser potentiometer signal is out of range for the forward position Synchroniser did not move toward reverse, even at maximum pressure Synchroniser did not move toward forward, even at maximum pressure Synchroniser pot signal is out of range for the 4 position Synchroniser pot signal is out of range for the 5 position Synchroniser did not move toward 4, even at max pressure Synchroniser did not move toward 5, even at max pressure No 12 V : no power for C3 and C4 solenoids Synchroniser cannot be engaged Range lever not in the high range position Low oil temperature < 10 - 60 °C (50.0 - 140 °F) High oil temperature > 105 °C (221.0 °F)

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Electrical systems - Electronic modules

CALIBRATION LIFT NOTE: Before the valve calibration procedure is performed, it is important that the hitch position sensor top position has first been calibrated. If fault code 1024 is displayed, then the position sensor calibration has not been performed. This position calibration is not performed using the H menu system

Position calibration The EDC (electronic draft control) position calibration is performed by a shortcut (then without management through HH menu). This procedure reset all hitch calibration but not solenoid calibration: 1.

Set all EDC (electronic draft control) panel potentiometers (see (1) , (2) , (3) , (4) image 9 ) fully clockwise and draft wheel (see (1) image 10 ) at max value. dosing unit (1). Slip limit control potentiometer (if radar is fitted) dosing unit (2). Raise limit potentiometer dosing unit (3). Drop rate control potentiometer dosing unit (4). Sensitivity potentiometer

WLAPL4S55C1035A

WLAPL4S55C1036A

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Electrical systems - Electronic modules

Hold hitch raise switch and Key ON; release the raise switch when the EDC (electronic draft control) status lamp ( (1), image 11 ) starts flashing (there is a 10 s window in which the switch must be released). This causes clearing of the calibrations for top and bottom of hitch travel, min and max for the quadrant, and min and max for the draft wheel.

The rockshaft top value is calibrated by raising the hitch until it stops moving. This calibration is invoked by setting the height limit to maximum, capturing the hitch, and raising the hitch by using the quadrant lever (position setting control).

When the hitch stops moving, the rockshaft pot value is stored as the calibrated value for rockshaft top. The hitch will then lower slightly, as the top 4 % of travel is not used in normal operation, to protect the hitch system from mechanical damage. This position at 96 % of total travel is considered 100 % hitch position.

Now the low value is calibrated by lowering the hitch until it stops moving at the bottom.

After calibrating turn the switch (1) to (A) (OFF) to save the calibrations.

WLAPL4S55C1038A

WLAPL4S55C1031A

Valve calibration NOTICE: Park on a flat surface and set the parking brake. The tractor can move during this procedure; make sure the area around the tractor is clear. Transmission output RPM is constantly monitored. Calibration cannot proceed unless the tractor is stopped. 1.

Disconnect all implements from the rear hitch.

Lower the linkage using the position control lever ( (1) 13 ) and connect to test weights. Test weights depends on implement to be mounted and must be sufficient to overcome any friction in the hydraulic lift assembly and enable the lift arms to lower without binding.

WLAPL4S55C1041A

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Electrical systems - Electronic modules

Key OFF the engine in (A) position.

WLAPL4S55C1031A

WLAPL4S55C1035A

MOIL13TR00868AA

MOIL13TR00872AA

Set all EDC (electronic draft control) panel potentiometers (see (1) , (2) , (3) , (4) 15 ) fully clockwise. dosing unit (1). Slip limit control potentiometer (if radar is fitted) dosing unit (2). Raise limit potentiometer dosing unit (3). Drop rate control potentiometer dosing unit (4). Sensitivity potentiometer

To enter the mode, you have two choices: Service Switch ( 380000843): Key ON and enter the mode using the service switch and navigate the H-tree by using the switches of the instrument cluster. Choose first product code RI, then mode H1 and eventually, confirming, the hitch symbol. Shortcut: hold down the work switch on the hand controller and start the vehicle. The system to be calibrated will be shown on the cluster and â&#x20AC;&#x153; CAL â&#x20AC;? will be displayed in the upper side of the display.

Set engine between 1100 - 1300 RPM. Engine speed must be stable, with no noticeable hunting or surging. If necessary, change the throttle setting slightly to achieve a stable engine RPM .

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Electrical systems - Electronic modules

Raise the control lever ( (1) image 18 ) to 70 % to 90 % to start calibration sequence. The upper side of the display will change from “ CAL ” to “ 0 ” to indicate start of calibration. During calibration the linkage is automatically raised and lowered a small amount 3 times, which takes 2-3 min. Each raise and lower is accompanied by a count on the display 0…1…2.

When display indicates “ End ” the calibration is complete.

Lower the linkage using the position control lever.

WLAPL4S55C1040A

WLAPL4S55C1031A

After calibrating turn the switch (1) to (A) (OFF) to save the calibrations or calibrate another subsystem.

NOTE: The error 1068 “Height Limit Calibration Error” (height limit control not turned fully clockwise or faulty) may be displayed during the procedure.

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Electrical systems - Electronic modules

Electronic module - H2 - View stored calibration values by the transmission (RI) Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H2 with the UP and DOWN buttons (2), press the ENTER button (1) to access the H2 menu.

WLAPL4S55C1007A

MOIL13TR00873AA

MOIL13TR00874AA

− Select the MENU H2 options with the UP and DOWN buttons ( (2) , 1 ) and press the ENTER button ( (1) , 1 ) to access the submenu. − After consulting the selected submenu, press the HOME button ( (1) , 1 ) to go back to the H2 menu where it is possible to move through the various menus.

Press the ENTER button ( (1) , 1) to access the submenu of the transmission. − The display will show the current clutch calibration values. − You can select the various channels by pressing the UP and DOWN button ( (2) , 1 ).

After displaying the channel number, the clutch or synchronizer letter will be displayed followed by the stored calibration value. Sequence indicates for example that the Clutch 1 calibration current value is 234 mA: ”Ch1....... C1........ 234” Description

Channel Ch1 Ch2 Ch3 Ch4 Ch5 Ch6 Ch7

Clutch 1 calibration current Clutch 2 calibration current Clutch 3 calibration current Clutch 4 calibration current Forward synchroniser calibration current Reverse synchroniser calibration current 1-4 synchroniser calibration current 47538922 29/05/2013

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Description 5-8 synchroniser calibration current Forward synchroniser calibration position Reverse synchroniser calibration position 1-4 synchroniser calibration position 5-8 synchroniser calibration position

Channel Ch8 Ch9 Ch10 Ch11 Ch12

EDC (electronic draft control) calibration values Press the ENTER button ( (1) , 1 ) to access the submenu of the lift. − The display will show the current clutch calibration values. − You can select the various channels by pressing the UP and DOWN button ( (1) , 1 ). − After displaying the channel number, „R‟ or „L‟ symbol will be displayed, followed by the stored calibration values. To exit menu, press HOME button.

MOIL13TR00875AA

Channel

Solenoid valve value Raise Solenoid calibration value Lower Solenoid calibration value

Ch1 Ch2

Standard value 20 - 80 mA 20 - 80 mA

NOTE: The predefined calibration values are: Raise solenoid valve − 50 mA. Lowering solenoid valve − 50 mA.

PTO calibration values Press the ENTER button ( (1) , 1 ) to access the submenu of the PTO. − The display will show the current PTO calibration values. − You can select the various channels by pressing the UP and DOWN button ( (1) , 1 ). − The channel number will be displayed, followed by the stored calibration values. To exit menu, press HOME button.

MOIL13TR00914AA

Channel Ch1 Ch2 Ch3

Item PTO Oil temperature [live] PTO Clutch Solenoid calibration value PTO clutch quick fill value

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Range Temperature dependent 100 - 420 2 to 19

Electrical systems - Electronic modules

Electronic module - H3 - Configurations and options of the module (RI) Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H3 with the UP and DOWN buttons (2), press the ENTER button (1) to access the H3 menu.

WLAPL4S55C1007A

MOIL13TR00876AA

MOIL13TR00877AA

− Select the MENU H3 options with the UP and DOWN buttons ( (2) , 1 ) and press the ENTER button ( (1) , 1 ) to access the submenu. − After making the modifications to the options of the various channels press the UP or DOWN button ( (1) , 1), for a period of 1 s an acoustic signal will be emitted for saving and the program will automatically return to the H3 menu where it is possible to move between the various HH menus. − If you do not intend to make any changes, press the HOME button ( (1) , 1 ) to go back to the H3 menu where it is possible to move through the various HH menus.

TRANSMISSION Channel 1 Creeper option enable − Select the transmission submenu with the ENTER button (1) , 1 ). − Select the transmission channel ( ch1 ), creeper option, with the UP or DOWN button ( (1), 1 ), the display will show these options: YES enabled no disabled, (default option) − Select the desired option with the UP and DOWN button ( (1) , 1 ).

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Electrical systems - Electronic modules

Channel 2, 3, 4, 5 Quick fill clutches 1, 2, 3, 4 − Select the transmission channel ( ch 2, 3, 4 and 5) with the UP and DOWN button ( (1) , 1 ). − It is possible to vary the quick filling time of each clutch from 30 ms to 150 ms (thousandths of a second) in steps of 10 ms, again with the UP and DOWN button ( (1) , 1).

MOIL13TR00878AA

Channel 2 3 4 5

Item Clutch 1 quick fill adjustment Clutch 2 quick fill adjustment Clutch 3 quick fill adjustment Clutch 4 quick fill adjustment

Range 30-150 30-150 30-150 30-150

Unit

Default 60 60 40 40

ms ms ms ms

Channel 6 Park lock enable / disable − Select the transmission channel ( ch6 ) with the UP and DOWN button ( (1) , 1 ). − Channel is used to select whether the park lock option is enabled or disabled. Display will show: YES enabled (park lock fitted) no disabled (park lock not fitted), default option. − Select the desired option with the UP and DOWN buttons ( (1) , 1 ).

MOIL13TR00879AA

MOIL13TR00880AA

Channel 7 Driver selectable shuttle modes − Select the transmission channel ( ch7 ) with the UP and DOWN button ( (1) , 1 ). − Channel is used to select memory shuttle: ( YES ) and ( no ) (default option), indicating whether memory shuttle is selected or not. Select the desired option using the UP and DOWN buttons ( (1) , 1). NOTE: An alternative shortcut method is also available to allow the shuttle mode to be selected without the use of a service switch. Enter the shortcut mode by holding the shuttle lever in the forwards position with the neutral button pressed and the clutch pedal up while turning the keyswitch ON. When the memory shuttle option is shown, after a few seconds display will show “ YES ” or “ no ” and the shuttle mode can then be selected using the same procedure as above.

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Electrical systems - Electronic modules

Channel 8 Large tyre option − Select the transmission channel ( ch8 ) with the UP and DOWN button ( (1) , 1 ). − Channel is used to describe how the operator can set the rear tyre radius. The display will show: 34 (for machines with rear wheel diameter 34" ), inches 38 (for machines with rear wheel diameter 38" ) inches, default setting Select the desired option using the UP and DOWN buttons ( (1) , 1).

MOIL13TR00881AA

MOIL13TR00882AA

EDC (Electronic Draft Control) Channel 1 EDC hydraulic selection − Select the electronic lift submenu, channel ( ch1 ) with the UP and DOWN button ( (1) , 1 ). − The display can change between 6 settings, in fact GPS vehicles offer 3 ram configurations available (“ r0 ”, “ r1 ” and “ r2 ” for every admitted arrangement of internal ram and two auxiliary rams) for 2 electro-hydraulic configurations ( EHR23 and EHR5 ). − Select the desired setting and indicate which ram option is selected using the UP and DOWN buttons ( (1) , 1). NOTE: The default setting for this option is “ def ”. If “ def ” is displayed, then this channel must be used to select the appropriate ram configuration, otherwise fault code 1070 will be shown. Valve type EHR23 EHR23 EHR23 EHR5 EHR5 EHR5

Option

Ram 1 1 1 1 1 1

int. int + int + int. int + int +

“ “ “ “ “ “

1 ext 2 ext 1 ext 2 ext

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A r0 ” A r1 ” A r2 ” b r0 ” b r1 ” b r2 ”

Electrical systems - Electronic modules

Channel 2 Enable / Disable EDC system NOTE: This channel is used to enable or disable the EDC system. The state of the system reflect the value shown in this channel: in fact, following an H8 of the EDC system or the fitting of a new central control unit CCU controller to the tractor, an automatic detection procedure will take place to determine if the vehicle is fitted with the controls for EDC , and the system will be enabled or disabled as appropriate. − Select the electronic lift submenu with the ENTER button (1) , 1 ). − Select the electronic lift channel ( ch2 ) with the UP and DOWN button ( (1) , 1 ). - The display will show: YES enable EDC system, (for machines with EDC), no disable EDC system, (for machines without EDC), default option - Select the desired option using the UP and DOWN buttons ( (1) , 1).

MOIL13TR00883AA

Channel 3 Enable / Disable slip control NOTE: This feature is available if the Radar is fitted. − Select the electronic lift channel ( ch3 ) with the UP and DOWN button ( (1) , 1 ). - The display will show: YES enable slip control (for machines with radar), no disable (for machines without radar), default option - Select the desired option using the UP and DOWN buttons ( (1) , 1). NOTE: If the “Enable/Disable EDC System” option is disabled by using channel 2 or by an automatic detection, as default the Slip control option will also be disabled. MOIL13TR00884AA

MOIL13TR00885AA

REAR PTO Channel 1 Auto PTO enabling option − Select the rear PTO submenu with the ENTER button ( (1) , 1 ). − Select the rear PTO channel ( ch1 ) with the UP and DOWN button ( (1) , 1 ). - The display will show: YES auto PTO is enabled no auto PTO is disabled (default option) Select the desired option using the UP and DOWN buttons ( (1) , 1)

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Electrical systems - Electronic modules

Channel 2 Rear PTO fender switches configuration − Select the rear PTO channel ( ch2 ) with the UP and DOWN button ( (1) , 1 ). − The display will show: YES enable (for machines with PTO fender switches fitted), no disable (for machines with PTO fender switches not fitted), default option − Select the desired option using the UP and DOWN buttons ( (1) , 1).

MOIL13TR00886AA

MOIL13TR00915AA

MOIL13TR00916AA

Channel 3 Rear PTO clutch calibration adjustment − Select the rear PTO channel ( ch3 ) with the UP and DOWN button ( (1) , 1 ). − The display will change to show the clutch calibration value. The UP button can then be used to increase the calibration value and the DOWN button to decrease the calibration value. − Select the desired value using the UP and DOWN buttons ( (1) , 1).

Channel 4 PTO quick fill time − Select the PTO channel ( ch4 ) with the UP and DOWN button ( (1) , 1 ). − The display will change to show the current value of the PTO quick fill time. The UP button can then be used to change the displayed value between “ 2 ” and “ 19 ” (clutch quick fill value is a parameter inside the software). − Select the desired value using the UP and DOWN buttons ( (1) , 1).

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Electrical systems - Electronic modules

Channel 5 Rear PTO groundspeed enabling option − Select the PTO channel ( ch5 ) with the UP and DOWN button ( (1) , 1 ). − The display will show: YES enable rear PTO groundspeed option no disable rear PTO groundspeed option, (default option) − Select the desired option using the UP and DOWN buttons ( (1) , 1).

MOIL13TR00887AA

MOIL13TR00888AA

MOIL13TR00889AA

FRONT PTO Channel 1 Front PTO selection − Select the front PTO channel ( ch1 ) with the UP and DOWN button ( (1) , 1 ). − The display will show: YES enable front PTO option no disable front PTO option, (default option) − Select the desired option using the UP and DOWN buttons ( (1) , 1).

DIFFERENTIAL LOCK AND FOUR WHEEL DRIVE Channel 1, 2, 3 Not used These channels are not used and “- - - -” will be displayed.

Channel 4 Four wheel drive braking speed selection − Select the differential lock and four wheel drive channel ( ch4 ) with the UP and DOWN button ( (1) , 1 ). − This option is used to select the ground speed below which four-wheel braking will not occur. To provide four-wheel braking, FWD clutch shall be engaged whenever both brake pedals are pressed: this activation shall be subjected to a minimum vehicle speed for four-wheel braking to be set in this H3 channel. The display will show option between “0” and “4”, these values correspond to the wheel speeds reported in following table. − Select the desired option using the UP and DOWN buttons ( (1) , 1). 4WD disengage speed

Option 0 1

0 km/h (0.0 mph) 1.6 km/h (1.0 mph)

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Electrical systems - Electronic modules

4WD disengage speed

Option 2 3 4

3.2 km/h (2.0 mph) 4.8 km/h (3.0 mph) 6.4 km/h (4.0 mph)

FRONT EHR (electro hydraulic remotes) Channel 1 Front EHR enable − Select the front EHR (electro hydraulic remotes) channel ( ch1 ) with the UP and DOWN button ( (1) , 1 ). − The display will show: YES enable front EHR option no disable front EHR option, (default option) − Select the desired option using the UP and DOWN buttons ( (1) , 1).

MOIL13TR00890AA

MOIL13TR00891AA

Channel 2 Front loader selection − Select the front EHR (electro hydraulic remotes) channel ( ch2 ) with the UP and DOWN button ( (1) , 1 ). − This channel is used to select if the front EHRs are used in conjunction with the front loader. The UP and DOWN buttons are used to cycle between the 2 available options: “ LoAd ” and “ nonE ”, that correspond to front loader or neither. When “ nonE ” is selected (default option), then all front EHR valves will be available for use. − Select the desired option using the UP and DOWN buttons ( (1) , 1).

Channel 3 Not used This channel is not used and “- - - -” will be displayed.

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Electrical systems - Electronic modules

Channel 4 Numbers of EHRs present NOTE: When the module is new or the H8 procedure is completed, automatic detection for the number of remotes is used. If at any time the number of fitted remotes needs to be changed then this setup channel is used. − Select the front EHR (electro hydraulic remotes) channel ( ch4 ) with the UP and DOWN button ( (1) , 1 ). − After the selection of channel 4, the current number of remotes stored is displayed (“ 1 ” or “ 2 ”). Use UP or DOWN button to toggle the setting to the new required number of remotes. − Select the desired value using the UP and DOWN buttons ( (1) , 1).

MOIL13TR00892AA

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Electrical systems - Electronic modules

Electronic module - H4 - View software revision level of the module (RI) Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H4 with the UP and DOWN buttons (2), press the ENTER button (1) to access the MENU H4 program.

WLAPL4S55C1007A

MOIL13TR00728AA

− The display will show the identification numbers of the control unit software release in sequence: 1476 − Software type. 01 − Main release. 00 − Secondary release. 01 − Development project. 00 − Development iteration. − At the end of the procedure, auto kick out to H4 , from here it is possible to move through all the menus HH . NOTE: The software version displayed by H4 may match the software version indicated on the label of module if the new software has been downloaded to module after manufacture. Four dashes will indicate end of the visualization.

not the the the

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Electrical systems - Electronic modules

Electronic module - H5 - Switch operation test for the module (RI) NOTE: This menu is used to check for transitions on switch for diagnostic purposes. On analog inputs, a “transition” means that a fixed threshold was crossed. The display shows a “d_ _” plus a number that indicates which circuit had a transition and beeps momentarily whenever a transition occurs. The number displayed indicates which circuit had a transition. This menu also checks for disagreement of the shuttle lever forward, neutral and reverse switches. The neutral switch is not tested separately with its own “d” number, because the operator has no way to cause a transition on the neutral switch without simultaneously causing a transition on the forward or reverse switch.

Shuttle lever test If the shuttle lever is shifted with the clutch pedal up, the neutral switch will also cause a transition on 12 V , which is used to test the clutch pedal switch. Because of the interaction of these switches: the forward and reverse switches must be tested with the clutch pedal down; the clutch pedal switch must be tested with the shuttle lever in gear, not in neutral; if the key switch is turned to the “crank” position with the shuttle lever in neutral and the clutch pedal down (normal starting procedure) a switch disagreement error can occur (only in diagnostic mode). When a low-high transition occurs on the clutch pedal switch (pedal moving up), the clutch pedal calibration values are checked and the switch adjustment is checked. To ensure proper check-out: 1. enter switch diagnostics mode with the clutch pedal fully up; 2. depress the clutch fully and pause at least one second; 3. slowly release the clutch pedal (two second min. from down to up). Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H5 with the UP and DOWN buttons (2), press the ENTER button (1) to access the MENU H5 .

WLAPL4S55C1007A

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Electrical systems - Electronic modules

− The display will show a “ d_ _ ”, as indicated in the figure. On detection of a switch transition, the display will show “ d ” followed by the switch number for which the transition was detected: if multiple switch transitions are detected then the display will show each circuit in turn. The display will also show “ d0 ” if a transition occurs on a switch input which is undefined for the module. − Press the ENTER button ( (1) , 1 ) to go back to the H5 menu where it is possible to move through the various HH menus. MOIL13TR00729AA

MOIL13TR00730AA

VAR Code d1 d2 d4

d5 d6 d8 d12 d13 d14 d15 d16 d17 d18 d19 d20 d21 d22

Description Fender EDC (electronic draft control) Lower Switch Fender EDC (electronic draft control) Raise Switch EDC (electronic draft control) Raise/Work Fault Switch EDC (electronic draft control) Work Switch EDC (electronic draft control) Raise Switch Cranking Switch Left Brake Switch Right Brake Switch Clutch Pedal Switch (12VD) Shuttle Lever Forward Switch Shuttle Lever Reverse Switch Gear Shift Downshift Switch Gear Shift Upshift Switch Gear Shift Second Function Switch Creeper Rail Status Switch Creeper Not Rail Status Switch Creeper Command Switch

Electrical system code S-003 S-004

CCU pin(**) X-210 30

S-003 S-004

X-210 29

A-011

X-230 6

A-011

X-210 18

A-011

X-210 20

S-035 S-021 S-022 S-035 S-034

X-230 X-210 X-210 X-230 X-210

S-034

X-210 13

A-014 A-014 A-014

X-230 11 X-230 10 X-230 4

S-065 S-066

X-210 21 X-210 28

S-049

X-230 16

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14 22 23 14 12

Electrical systems - Electronic modules

Code d23 d24 d25 d31 d33 d38 d39 d41 d42 d44 d45 d47 d48 d49 d51 d63 d64 d90 d91 d153 d154 d155 d158 d159

d164 d165

d168 d170

Description Shuttle Lever Forward or Reverse Switch Shuttle Lever Neutral Switch Park Lock Switch Air Conditioning Switch Radar Present Switch Manual Differential lock Switch Auto Differential lock Switch Manual 4WD Switch Auto 4WD Switch Rear PTO NO Switch Rear PTO NC Switch Rear PTO Brake Switch Rear PTO Groundspeed Switch Rear PTO Auto Switch Differential lock Clutch Status Switch Rear PTO Fender NO Switch Rear PTO Fender NC Switch Front PTO NO Switch Front PTO NC Switch Joystick - Button 1 (black) Joystick - Button 2 (yellow) Joystick - Button 3 (green) Reactivity Switch EHR (electro hydraulic remotes) Encoder Enter Switch Hydraulic Master Switch EHR (electro hydraulic remotes) Float Control Switch Range H Switch Range L Switch

Electrical system code S-034

CCU pin(**) X-230 15

S-034

X-230 13

S-067 S-013 B-029 S-011

X-210 X-230 X-210 X-240

11 25 19 31

S-011 S-010 S-010 S-007 S-007 S-058 S-009

X-240 X-230 X-230 X-240 X-240 X-230 X-230

30 24 1 11 23 8 17

S-057 S-062

X-230 12 X-210 26

S-005 S-006

X-230 21

S-005 S-006

X-230 20

S-008 S-008 S-075 S-075 S-076 S-036 S-060

X-240 X-230 X-220 X-240 X-240 X-240 X-230

S-059 S-061

X-230 3 X-210 24

S-033 S-032

X-230 18 X-230 5

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32 22 18 27 28 33 26

Electrical systems - Electronic modules

Electronic module - H6 - Vehicle information view on the transmission (RI) Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. â&#x2C6;&#x2019; Select the MENU H6 with the UP and DOWN buttons (2), press the ENTER button (1) to access the MENU H6 program.

WLAPL4S55C1007A

MOIL13TR00917AA

Once pressed enter button, the number of gears, transmission speed and engine horsepower will be displayed in succession.

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Electrical systems - Electronic modules

Electronic module - H7 - Vehicle test modes on the central control unit (RI) Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H7 with the UP and DOWN buttons (2), press the ENTER button (1) to access the MENU H7 program.

WLAPL4S55C1007A

MOIL13TR00895AA

“ ch _ _ ” will appear in the display on the instrument cluster. − You can select the various channels by pressing the UP and DOWN buttons (1). − After a short timeout, the cluster will display specific information depending on the channel number selected. − Press the HOME button (1) to go back to the H7 menu where it is possible to move through the various HH menus.

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Electrical systems - Electronic modules

Clutch pedal switch test − Select the ch1 channel, with the UP and DOWN buttons ( (2) , 1 ), move the Power Shuttle control lever into the forward drive position. The display will show “ n ” if the lever is in neutral. − When the display shows “ CP ”, cycle the clutch pedal. − When the clutch pedal is released the display will show a value in the range 8 to 14 if the switch is correctly adjusted. − If the switch is incorrectly adjusted the display will show “ CL ” if clutch pedal switch adjustment screw is to be turned clockwise or “ CCL ” if the screw is to be turned anti-clockwise. − Adjust the screw in the direction indicated on the display and cycle the clutch pedal and the procedure until the display shows the correct value.

MOIL13TR00894AA

MOIL13TR00896AA

MOIL13TR00897AA

Forward/Reverse synchroniser test − Select the ch2 Select the channel, with the UP and DOWN buttons ( (2) , 1 ). − The synchro position is displayed on the central display (range 20-80). − Press the upshift button to increase the forward synchro solenoid pressure. − Press the downshift button to increase the reverse synchro solenoid pressure.

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Electrical systems - Electronic modules

Manual adjustment of the quick fill values − Select the ch3 Select the channel, with the UP and DOWN buttons ( (2) , 1 ). − The synchro position is displayed on the central display (range 20-80). − Press the upshift button to increase the 4 to 5 synchro solenoid pressure. − Press the downshift button to increase the 5 to 4 synchro solenoid pressure. − Press both the upshift & downshift buttons to move the synchro to the neutral position.

MOIL13TR00898AA

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Electrical systems - Electronic modules

C1/C2 manual calibration and quick fill adjustment NOTE: Ensure that the tractor is parked on hard level ground, the handbrake is released, the range lever is in the high range position and that the transmission oil temperature is above 60 °C (140.0 °F). − To make the modification the operator must be seated in the driving seat. − Select the ch4 channel with the UP and DOWN buttons ( (2) , 1 ), with the shuttle lever in neutral and the clutch pedal raised, the display will show the oil temperature. − To adjust and test the C1 values, select 12th gear. The display will show " C1 ". Fully depress the clutch pedal and move the shuttle lever into the forward position. The clutch calibration value for C1 will be displayed. − The range switch is used to switch the display between the clutch calibration value and the clutch quick fill time. − To adjust the clutch calibration value first ensure that the display is showing the calibration value. If the display is currently showing the quick fill time then use the range switch to change back to the calibration value. Fully depress the clutch pedal and use the upshift and downshift switches to adjust the calibration value either up or down. − To test the calibration value completely release the clutch pedal, then depress it slightly and release it. The correct value has been achieved if the tractor starts to creep. − To adjust the clutch quick fill value first ensure that the display is showing the quick fill value. If the display is currently showing the calibration value then use the range switch to change to the quick fill value. Fully depress the clutch pedal and use the upshift and downshift switches to adjust the quick fill value either up or down. Values in the range 3 to 19 may be selected. − To test the quick fill value completely release the clutch pedal, then depress it slightly and release it. For a proper adjustment the transmission oil must be above 85 °C (185.0 °F). For a good setting no perceivable kick must be felt, just a creep due to the calibration value. − To adjust and test the C2 values, put the transmission into neutral, and repeat from step 3 but select 13th gear.

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MOIL13TR00899AA

Electrical systems - Electronic modules

C3/C4 manual calibration and quick fill adjustment NOTE: Ensure that the tractor is parked on hard level ground, the handbrake is released, the range lever is in the high range position and that the transmission oil temperature is above 60 °C (140.0 °F). − To make the modification the operator must be seated in the driving seat. − Select the ch5 channel with the UP and DOWN buttons ( (2) , 1 ), with the shuttle lever in neutral and the clutch pedal raised, the display will show the oil temperature. − To adjust and test the C3 values, select 12th gear. The display will show " C3 ". Fully depress the clutch pedal and move the shuttle lever into the forward position. The clutch calibration value for C3 will be displayed. − The range switch is used to switch the display between the clutch calibration value and the clutch quick fill time. − To adjust the clutch calibration value first ensure that the display is showing the calibration value. If the display is currently showing the quick fill time then use the range switch to change back to the calibration value. Fully depress the clutch pedal and use the upshift and downshift switches to adjust the calibration value either up or down. − To test the calibration value completely release the clutch pedal, then depress it slightly and release it. The correct value has been achieved if the tractor starts to creep. − To adjust the clutch quick fill value first ensure that the display is showing the quick fill value. If the display is currently showing the calibration value then use the range switch to change to the quick fill value. Fully depress the clutch pedal and use the upshift and downshift switches to adjust the quick fill value either up or down. Values in the range 3 to 19 may be selected. − To test the quick fill value completely release the clutch pedal, then depress it slightly and release it. For a proper adjustment the transmission oil must be above 85 °C (185.0 °F). For a good setting no perceivable kick must be felt, just a creep due to the calibration value. − To adjust and test the C4 values, put the transmission into neutral, and repeat from step 3 but select 13th gear.

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MOIL13TR00901AA

Electrical systems - Electronic modules

Electronic module - H8 - Clear stored calibration information (EEPROM) on the central control unit (RI) Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H8 with the UP and DOWN buttons (2), press the ENTER button (1) to access the H8 menu. This mode (common to all subsystems) clears calibration values and error codes in EEPROM bringing them back to defaults.

WLAPL4S55C1007A

MOIL13TR00731AA

MOIL13TR00732AA

NOTE: EEPROM is where all calibration values and error codes are stored. This memory is retained even if there is no power to the module, i.e. if the battery is disconnected. This should be used if a module is moved from one tractor to another. NOTE: Making an H8 , the settings in H3 are kept and not deleted as well. ALL − Deletes everything concerning the control units irrespective of function, OPTIONS/SUBSYSTEMS: electronic lift, transmission, PTO, Differential lock and 4WD, EHR (electro hydraulic remotes) For a control module, each subsystem can be cleared individually or, by selecting the module identifier, the settings for the whole module can be erased. Use the HC menu if it is required to erase all stored error codes without erasing calibration information. Making an H8 , the settings in H3 are kept and not deleted as well. − The display will show EECL . − To delete the memory you need to keep the DOWN button ( (2), 1 ) pressed until the procedure is completed, that is when the display shows EE . NOTE: If the button is released during the countdown, the values will not be deleted the visualization will return to EECL.

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Electrical systems - Electronic modules

â&#x2C6;&#x2019; It is not possible to return to the top level HH menu after an H8 procedure has been performed. â&#x2C6;&#x2019; The only permitted action is to turn the switch (1) to (A) (OFF).

WLAPL4S55C1021A

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Electrical systems - Electronic modules

Electronic module - H9 - Voltmeter diagnostic of the central control unit (RI) Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H9 with the UP and DOWN buttons (2), press the ENTER button (1) to access the H9 menu.

WLAPL4S55C1007A

MOIL13TR00733AA

− “ ch _ ” will appear in the top area of LCD display on the instrument cluster. − You can select the various channels by pressing the UP and DOWN buttons ( (2) , 1 ). − Once channel has been chosen, the display will change to show the corresponding reading. − Press the ENTER button ( (1) , 1) to go back to HH MENU .

ch 10 11 14 33 34 35 36 37 40 41 44 45 48 56 86 87 91 97 98 99 100 101 102 103

Description Left-hand draft sensing pin Right-hand draft sensing pin Transmission oil temperature Position control Drop rate control potentiometer Height limit potentiometer Sensitivity control potentiometer Max slip control potentiometer Draft control potentiometer Neutral switch F/R Synchroniser position 4/5 Synchroniser position Clutch pedal potentiometer Transmission oil pressure Reverse switch Forward switch Rockshaft position Joystick - X position Joystick - Y position Wheel speed sensor DC diagnostic Clutch 3 solenoid cursen Clutch 4 solenoid cursen Clutch 1 solenoid cursen Clutch 2 solenoid cursen

CCU pin(*) X-210 10 X-210 9 X-210 14 X-210 3 X-210 4 X-210 5 X-210 6 X-210 7 X-210 8 X-230 13 X-210 1 X-230 2 X-230 7 X-230 19 X-210 13 X-210 12 X-210 2 CAN CAN X-240 20 X-240 1 X-240 2 X-240 3 X-240 4

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Component code B-003 B-004 B-008 A-011 B-002 B-002 B-002 B-002 A-011 S-034 B-031 B-030 B-010 B-032 S-034 S-034 B-001 CAN2L CAN2H B-009 Y-011 Y-012 Y-009 Y-010

Typical Reading 830 - 7680 mV 830 - 7680 mV 340 - 4510 mV 400 - 4600 mV 400 - 4600 mV 400 - 4600 mV 400 - 4600 mV 570 - 4430 mV 400 - 4600 mV 700 - 4200 mV 300 - 4700 mV 300 - 4700 mV 220 - 4840 mV 250 - 4750 mV 700 - 4200 mV 700 - 4200 mV 125 - 4640 mV 0 100 0 100 840 - 2520 mV 0 - 750 mA 0 - 750 mA 0 - 750 mA 0 - 750 mA

Electrical systems - Electronic modules

ch 108 111 112 114 118 121 122 123 124 137 138

164 166 203 204

Description

CCU pin(*)

Typical Reading

5/8 synchro solenoid cursen Creeper solenoid cursen 1/4 synchro solenoid cursen Forward synchro solenoid cursen Reverse synchro solenoid cursen EDC (electronic draft control) raiser solenoid current EDC (electronic draft control) lower solenoid current Rear PTO solenoid cursen Front PTO solenoid cursen PTO speed sensor DC diagnostic Rear PTO groundspeed switch

X-220 3 X-220 13 X-220 6 X-240 10 X-220 2 X-220 4

Component code Y-030 Y-026 Y-029 Y-027 Y-028 Y-001

X-220 5

Y-002

0 - 3350 mA

X-240 18 X-220 7 X-240 19 X-230 17

Y-003 Y-004 B-005 S-009

EHR (electro hydraulic remotes) encoder 1 sensor EHR (electro hydraulic remotes) encoder 2 sensor 12 V (VD) 12 V (VF)

X-220 14

S-060

0 - 750 mA 0 - 750 mA 3 85 700 - 4200 mV 1510 mV if released 3410 mV if pressed 50 - 4950

X-220 20

S-060

50 - 4950

0 0 0 0 0 0

750 mA 750 mA 750 mA 750 mA 750 mA 3350 mA

X-200 8 9000 - 16000 mV 9000 - 16000 mV X-200 1 X-200 2 X-200 3 207 X-200 20 9000 - 16000 mV 12 V (VH) 213 X-240 34 9000 - 16000 mV 12 V (VT) 216 8 V sensors supply X-210 25 7000 - 9000 mV 217 5 V sensors supply X-210 17 4200 - 5800 mV * - Refer to the "System diagram" of the central control unit CCU (see Wire harnesses - Electrical schema CCU CONTROL UNIT (55.100) )

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Electrical systems - Electronic modules

Electronic module - HB - Display stored fault codes on the central control unit (RI) Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU HB with the UP and DOWN buttons (2), press the ENTER button (1) to access the submenu.

WLAPL4S55C1007A

MOIL13TR00734AA

MOIL13TR00735AA

− Select the subsystem module with the UP and DOWN buttons ( (2) , 1 ), press the ENTER button ( (1) , 1) to view the codes of the selected submenu.

− If no errors are present in the selected subsystem, “ - - - ” will be displayed and you cannot select subsystem; otherwise, if an error is present for the selected subsystem, “ F ” is displayed in the top area of the screen. − You can select the various faults by pressing the UP and DOWN buttons ( (2) , 1 ). − When the first error will be displayed, data sequence will appear on upper display as follows: 1. “error code”, then 2. “absolute hour of the first occurrence”, then 3. “absolute hour of last occurrence”, then 4. “occurrence of fault”. − The same error will be displayed again. − Press the UP and DOWN buttons ( (2) , 1 ) you can scroll on display to select each error.

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â&#x2C6;&#x2019; The only permitted action is to turn the switch (1) to (A) (OFF).

WLAPL4S55C1021A

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Electronic module - HC - Clear all stored fault codes on the central control unit (RI) Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU HC with the UP and DOWN buttons (1), press the ENTER button (1) to access the MENU HC .

WLAPL4S55C1007A

MOIL13TR00736AA

WLAPL4S55C1021A

− The central display will show F CL. − To delete the code memory you need to keep the DOWN button ( (2) , 1 ) pressed until the countdown procedure is completed, that is when the display shows EE , now release the button. NOTE: If the button is released during the countdown, deletion will not take place.

− The only permissible operation is to turn the key (1) to (A) (OFF) to save.

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Electrical systems - Electronic modules

Electronic module - HE - Display frequency inputs on the central control unit (RI) NOTE: This mode is common to all subsystems and allows service personnel to verify the operation of various frequency inputs. In this mode, the vehicle is operable. Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU HE with the UP and DOWN buttons (1), press the ENTER button (1) to access the MENU HE .

WLAPL4S55C1007A

MOIL13TR00737AA

− The display will show ch _ press the UP and DOWN button ( (2) , 1 ) the selected channel number followed by the related measurement. Channel numbers can be not consecutive, for unused channels “ - - - - ” will be displayed. − Press the ENTER button ( (1) , ) to go back to the HE menu where it is possible to move through the various HH menus.

Description

ECU pin(*)

3 Engine speed B-022 CAN 4 X-240 19 B-005 PTO speed 5 Wheel speed X-240 20 B-009 6 Radar speed X-210 33 B-029 (*) Refer to the "System diagram" of the central control unit CCU (see Wire harnesses CCU CONTROL UNIT (55.100) ).

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Typical Reading 0 - 2700 RPM 0 - 2550 Hz 0 - 3500 Hz 0 - 14720 Hz Electrical schema

Sens. code

Electrical systems - Electronic modules

Electronic module - HF - View controller hardware information central control unit (RI) Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU HF with the UP and DOWN buttons (1), press the ENTER button (1) to access the above-mentioned MENU HF .

− The display will show the identification numbers of the control unit hardware release in sequence: 795 = hardware module identification (in this case RI, central control module) 04.00.00.00 = hardware module release identification 0000. 3001. 0376 = serial number (printed on the control unit label). Note that the serial number shown on the display will include leading zeros that may not be present on the module label. In this example, the serial number is 30010376. - At the end of the procedure you are automatically returned to HF where you can navigate among the various HH menus. NOTE: Hardware Identifier: – ZD module ( ADIC ): 790 ( 40 km/h (24.9 mph)) or 808 ( 35 km/h (21.7 mph)) – OA tractor engine control module ( TECU ): 501 (optional)

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WLAPL4S55C1007A

MOIL13TR00738AA

Electrical systems - Electronic modules

Electronic module - HJ - Electronic hydraulic remote control valve number programming of the central control module (RI) NOTE: Each EHR (electro hydraulic remotes) valve has its own built in processor which stores in its memory the valve’s number within the EHR stack. If it becomes necessary to replace a valve assembly, then it will be required to reprogram the number of each valve within the complete valve assembly. Replacement valve assemblies are supplied with no number assigned. Note that it is essential that the renumbering procedure for a complete set of valves, e.g. all front valves, must be completed in its entirety before commencing the procedure for the other set of valves. Access the HH MENU RI as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU HJ with the UP and DOWN buttons (1), press the ENTER button (1) to access the above-mentioned MENU HJ .

WLAPL4S55C1007A

MOIL13TR00912AA

WLAPL4S55C1021A

The display will change to show “ Eehr ”. Press and hold the DOWN button ( (2) , image 1) . The display will change to show “ 5 ” and countdown to “ 1 ”, then change to “ Cehr ”: this means that the valve numbers have been cleared.

Turn the key switch (1) to (A) position (OFF).

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Disconnect all the valves except valve number 1. Turn the key switch ( (1), image 3) to (B) position (ON) and select HJ menu once again, repeating the procedure in step 1. The instrument cluster will momentarily display “ Ehr_ ” followed by “ Ehr1 ” and an audible beep will be heard indicating that the first valve has been recognised and renumbered. The display will then change to flash “ Ehr2 ” to signify that the controller is ready for the next valve to be connected. As each valve is reconnected, an audible beep will signify that the valve is recognised and the display will change to show the next valve number to be reconnected until all the valves have been connected. Ensure that the audible beep has been heard or the display has changed indicating the next valve to be renumbered before reconnecting the next valve. If there are less than 2 remote valves, then the procedure can be terminated by pressing and holding the DOWN button ( (2) , image 1): the display will change to “ End ” to signify that the programming is complete. If the maximum number of valves is fitted, then the procedure will end automatically displaying “ End ”.

MOIL13TR00913AA

Turn the key switch ( (1) image 3) to the (OFF) position (A) to store the new valve numbers. NOTE: The following U codes may be displayed if a problem is encountered during the above procedures: U161: Incorrect sequence detected when renumbering the midmount valves Possible causes: the renumbering procedure for midmount valves has not been completed correctly. Pay particular attention to ensure that the last 2 steps in the renumbering procedure has been correctly completed.

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Index Electrical systems - 55 Electronic modules - 640 Electronic module - H1 - Calibration procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Electronic module - H2 - View stored calibration values by the transmission (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Electronic module - H3 - Configurations and options of the module (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Electronic module - H3 - Configurations and options of the control panel module (ZD) . . . . . . . . . . . . . . . . . . . . . . 14 Electronic module - H4 - View software revision level of the module (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Electronic module - H4 - View software revision level control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Electronic module - H5 - Switch operation test control switches (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electronic module - H5 - Switch operation test for the module (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Electronic module - H6 - Vehicle information view on the transmission (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Electronic module - H7 - Vehicle test modes on the central control unit (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Electronic module - H8 - Clear stored calibration information (EEPROM) (control panel) . . . . . . . . . . . . . . . . . . . . 22 Electronic module - H8 - Clear stored calibration information (EEPROM) on the central control unit (RI) . . . . . . 71 Electronic module - H9 - Voltmeter diagnostic of the central control unit (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Electronic module - H9 - Voltmeter diagnostic on control panel (ZD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Electronic module - HB - Display stored fault codes on control panel (ZD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Electronic module - HB - Display stored fault codes on the central control unit (RI) . . . . . . . . . . . . . . . . . . . . . . . . . 75 Electronic module - HC - Clear all stored fault codes on control panel (ZD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Electronic module - HC - Clear all stored fault codes on the central control unit (RI) . . . . . . . . . . . . . . . . . . . . . . . . 77 Electronic module - HE - Display frequency inputs on the central control unit (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Electronic module - HF - View controller hardware information central control unit (RI) . . . . . . . . . . . . . . . . . . . . . . 79 Electronic module - HF - View controller hardware information on control panel (ZD) . . . . . . . . . . . . . . . . . . . . . . . 40 Electronic module - HJ - Electronic hydraulic remote control valve number programming of the central control module (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Electronic module - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electronic module - View engine error codes list (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Electronic module - View list of differential lock error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Electronic module - View list of electronic lift error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Electronic module - View list of fourâ&#x2C6;&#x2019;wheel drive error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Electronic module - View list of transmission error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Electronic module - View rear PTO error code listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Electronic module - View HH MENU ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Electronic module - View HH MENU OF THE CONTROL PANEL (ZD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electronic module - View HH MENU OF THE TRANSMISSION (RI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Electronic modules - Fault code index Calibration U-code listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Warning indicators, alarms, and instruments - 408

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Electrical systems - 55 Warning indicators, alarms, and instruments - 408

FUNCTIONAL DATA Instrument cluster Dynamic description display information and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Dynamic description (ADIC) programmable display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dynamic description dashboard/display brightness adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dynamic description Speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Dynamic description implement width calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Dynamic description programming maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Dynamic description audible warning on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Dynamic description setting units of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Dynamic description of the DPF (Diesel Particulate Filter) regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Dynamic description oil change counter reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Dynamic description fault codes display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Static description alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Overview warnings on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Dynamic description setting hours worked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Dynamic description display information and actions Information Display The display shows information on the operational condition of the machine and highlights any trouble in the form of symbols or error codes. The display is subdivided into 5 parts giving the following information: Section 1 Rear power take-off shaft speed. Rear lift position. Slip (if radar is installed). Press and release the ENTER button ( (1) , 2 ) (press for less than 3 s ) to scroll through the various items of information. Section 2 Work hours Section 3 If the PMU option in H3 of the ZD control panel is on ( YES ) you can see: Odometer Worked area Estimated hourly area Battery voltage If the PMU option in H3 of the ZD control panel is off ( NO ) you can see only: Battery voltage Use the UP and DOWN button ( (2) , 2 ) to scroll through the various items of information. Section 4 Tractor speed

WLAPL4S55C107A

WLAPL4S55C1007A

WLAPL4S55C106A

NOTE: Sections 1 and 3 are also used to view the HH diagnostic programs, see specific chapter

VIEWING FUNCTIONS IN SECTION 3 Odometer The value will be displayed in miles or kilometers depending on the unit of measurement. Press the HOME button ( (1) , 2 ) for longer than 3 s to reset the odometer.

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Electrical systems - Warning indicators, alarms, and instruments

Area worked. This value is calculated by the control unit multiplying the width of the implement (set when setting up the ADIC ) by the distance traveled. The unit of measurement will be acres or hectares depending on the setting. Press and release the HOME button ( (1) , 2 ) to pass between the 3 screens: ON = ADIC always counts OFF = ADIC does not count A = L' ADIC counts when the implement is lowered Press for a time of 3 s , when OFF, to reset the value. WLAPL4S55C105A

WLAPL4S55C104A

WLAPL4S55C101A

WLAPL4S55C102A

Hourly area. An estimate of the area that can be worked in the next hour, based on the current speeds and the implement width. The unit of measurement will be acres or hectares depending on the setting.

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Electrical systems - Warning indicators, alarms, and instruments

Battery voltage The last item displayed is the battery voltage, this will also be displayed with the PMU option not enabled ( NO ).

WLAPL4S55C103A

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Dynamic description (ADIC) programmable display The multifunction liquid crystal display (1) can show useful and necessary information when driving and a menu for making the following adjustments: • Tractor speed calibration (only without the radar unit available on request). • Implement width. • Programmed maintenance. • Sound level on/off on pressing the buttons. • Units of measurement in km/h or MPH • Diesel particulate filter control (DPF). • Resetting oil change.

DCAPLT5NE044S3A

DCAPLT5NE045S3A

DCAPLT5NE047S3A

• Viewing active error codes and warning messages. The menu is navigated through by using the rocker switches (2) and (3). Each button provides two controls, depending on the position where it is pressed. To enter the “SETUP MENU”, it is necessary to turn the start switch key onto position (B), panel powered, and subsequently keep the switch (2) pressed on the symbol (B) for more than three seconds.

Switch (2) (A) Exit/Cancel. Use this switch position to cancel or quit the setting and programming modes. (B) Menu/Enter. Use this switch position to enter the menu or confirm the settings.

Switch (3) (C) Up arrow = scrolling up through the menu or numerical value. Press this switch position repeatedly to scroll forwards in the menu or change the value of a number. (D) Down arrow = scrolling down through the menu or numerical value. Press this switch position to scroll backwards in the menu or to move to the right of a position.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Dynamic description dashboard/display brightness adjustment NOTE: During this adjustment bear in mind that the illumination will always be greater with the position lights off, whereas with the lights on there will automatically be a decrease in illumination.

DCAPLT5NE065S3F

Brightness of warning lights and indicator pointers • With the panel powered, press and hold down the switch (3) on the symbol (C) for 3 seconds. • The central monitor will show the detail (S1) . • Release the direction key to pass on to the next screen (S2). • Press the switch (3) on the symbol (C) to increase or on the symbol (D) to decrease the brightness of the central display until you reach the desired brightness. • Press the switch (2) on the symbol (B) to save the setting. • Two seconds after saving you are automatically returned to the initial condition. NOTE: If you want to stop the adjustment without saving, press the switch (2) on the symbol (A) to exit the adjustment.

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Electrical systems - Warning indicators, alarms, and instruments

DCAPLT5NE066S3F

Central display brightness • With the panel powered, press and hold down the switch (3) on the symbol (D) for 3 seconds. • The central monitor will show the detail (S1) . • Release the direction key to pass on to the next screen (S2). • Press the switch (3) on the symbol (C) to increase or on the symbol (D) to decrease the brightness of the central display until you reach the desired brightness. • Press the switch (2) on the symbol (B) to save the setting. • Two seconds after saving you are automatically returned to the initial condition. NOTE: If you want to stop the adjustment without saving, press the switch (2) on the symbol (A) to exit the adjustment.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Dynamic description Speed calibration

DCAPLT5NE067S3F

NOTE: This setting is not present if the radar unit is installed. Check that the circumference of the fitted tyres is as shown on the “CAL manual” screen, otherwise it will be necessary to recalibrate the electronic control module to display the precise exact ground speed. It is possible to recalibrate the module, manually or automatically.

Manual Calibration • To calibrate the module manually, it is indispensable to know the rolling circumference (RC) of the new tyre. • Press the switch (2) on the symbol (B) for more than three seconds to enter the programming menu The central monitor will show “SETUP MENU”. Release the symbol (B); the display will show “CAL”. • Press and release the switch (2) on the symbol (B); the monitor will show “CAL manual”. • Press and release the switch (2) on the symbol (B). • Press the switch (3) on the symbol (C) to change the flashing value, press the symbol (D) to move to the next digit. In this way you enter the rolling circumference of the new tyre. • Press the switch (2) on the symbol (B) to save the new added measurement. If you want to stop the display, press the switch (2) on the symbol (A) . Press the same symbol again to exit the programming menu.

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Electrical systems - Warning indicators, alarms, and instruments

DCAPLT5NE067S3F

Auto Calibration • Select a stretch of dry, firm, level ground (preferably concrete) and carefully measure out a distance of exactly 100 m (328 ft) . Mark the start and finish of this measured distance with a bold chalk line. • Press the switch (2) on the symbol (B) for more than three seconds to enter the programming menu The central monitor will show “SETUP MENU” . Release the symbol (B); the display will show “CAL”. • Press and release the switch (2) on the symbol (B); the monitor will show “CAL manual”. • Press and release the switch (3) on the symbol (D); the monitor will show “CAL auto”. • Press and release the switch (2) on the symbol (B); the monitor will show “CAL READY”. • Now select a suitable gear to give a constant speed greater than 2 km/h (1.2 mph) , and, at the start of the drawn line, press and release the switch (2) on the symbol (B); the display will flash “CAL ON”. NOTE: The ground speed must be constant and must not drop under 2 km/h (1.2 mph). If the speed is less than as prescribed, calibration will not be successful. • When the middle of the front tyres goes over the end line, press the switch (2) again on the symbol (B) and, if the procedure has been performed correctly, the monitor will show “CAL OK“. Now press the switch (2) on the symbol (B) again to save the setting. If on the contrary the procedure has not been performed correctly the monitor will display “CAL NOT OK” and the procedure must be repeated. If you want to stop the procedure and quit the programming menu, repeatedly press the switch (2) on the symbol (A) If on the contrary you want to repeat the calibration, press the switch (2) on the symbol (A) until the display shows “CAL auto”. From this position, repeat the procedure, taking care that the tractor speed is constant and greater than 2 km/h (1.2 mph).

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Dynamic description implement width calibration

DCAPLT5NE068S3F

To calculate the work done, the working width of the implement in use must be entered into the memory. To set for example a working width of 4.5 m (14.8 ft) proceed as described below: • Press the switch (2) on the symbol (B) for more than three seconds to enter the programming menu The central monitor will show “SETUP MENU”. Release the symbol (B). • Press the switch (3) on the symbol (D) until you see screen S1. • Press the switch (2) on the symbol (B); The monitor will show the width of the implement used previously on the screen. If it is necessary to change this measurement, proceed as follows: • Press the switch (3) on the symbol (D) to decrease or (C) to increase the first digit. • Press and release the switch (2) on the symbol (B), to move onto the second digit. • If the entered implement width is correct, press the switch (2) on the symbol (B), after 2 seconds the monitor will show the new measurement of the implement just entered on the screen. Press the switch (2) again on the symbol (B) to save the new set width, or press the switch (2) on the symbol (A) and repeat the entire programming. NOTE: If you want to stop the procedure and quit the programming menu without changing the displayed implement width, repeatedly press the switch (2) on the symbol (A).

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Dynamic description programming maintenance work

DCAPLT5NE069S3F

This function enables the operator to schedule the maintenance work for two levels of importance: "routine (LIGHT) " or "important (HEAVY)". Proceed as follows: • Press the switch (2) on the symbol (B) for more than three seconds to enter the programming menu The central monitor will show “SETUP MENU”. Release the symbol (B). • Press the switch (3) on the symbol (D) a number of times until the monitor shows the symbol for programming the maintenance frequency (S1). • Press the switch (2) on the symbol (B); The monitor will show the screen “Heavy” with the hours remaining till the time for maintenance. The setting cannot be changed at this stage. • Press the switch (2) on the symbol (B) to change the setting of the first flashing digit (in the above example, the number “2”). • Press the switch (3) on the symbol (C) to increase the value. Press on the symbol (D) to move onto the next digit. • If you do not want to save the new setting and go back to the start of programming, repeatedly press switch (2) on the symbol (A). • To save the new maintenance schedule, press the switch (2) on the symbol (B). The monitor will display confirmation on saving the new value. • After two seconds you exit the maintenance work programming menu. NOTE: Near the time for the programmed work, the monitor will show the warning in hours of work remaining till maintenance. At the end of the count the monitor will show “Heavy “ followed by a warning message to indicate that the time has expired. At the end of the count, in the maintenance work programming menu, the counter will show three dashes and must be re-programmed as described above.

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Electrical systems - Warning indicators, alarms, and instruments

DCAPLT5NE070S3F

Setting routine maintenance work • Press the switch (2) on the symbol (B) for longer than three seconds to enter the programming menu. Release the symbol (B). • Press the switch (3) on the symbol (D) a number of times until the monitor shows the symbol for programming the maintenance frequency (S1). • Press the switch (2) on the symbol (B); The monitor will show the screen “Heavy” with the hours remaining till the time for maintenance. • Press the switch (3) on the symbol (D); The monitor will show the screen “Light” with the hours remaining till the time for maintenance. The setting cannot be changed at this stage. • Press the switch (2) on the symbol (B) to change the setting of the first flashing digit (in the above example, the number “5”). • Press the switch (3) on the symbol (C) to increase the value. Press on the symbol (D) to move onto the next digit. • If you do not want to save the new setting and go back to the start of programming, repeatedly press switch (2) on the symbol (A). • To save the new maintenance schedule, press the switch (2) on the symbol (B). The monitor will display confirmation on saving the new value. NOTE: Near the time for the programmed work, the monitor will show the warning in hours of work remaining till maintenance. At the end of the count the monitor will show “Light “ followed by a warning message to indicate that the time has expired. At the end of the count, in the maintenance work programming menu, the counter will show three dashes and must be re-programmed as described above.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Dynamic description audible warning on/off

DCAPLT5NE052S3A

If you want to turn the audible warning on or off each time a button is pressed, proceed as follows: • Press the switch (2) on the symbol (B) for more than three seconds to enter the programming menu The central monitor will show “SETUP MENU”. Release the symbol (B). • Press the switch (3) on the symbol (D) a number of consecutive times until the monitor shows ”BEEP ON/OFF”. • Press the switch (2) on the symbol (B); the monitor will show the last setting made, ”BEEP ON” or ”BEEP OFF”. Press the switch (3) on the symbol (D) or (C) to change the setting. • ”ON” = warning ”BEEP“ on • ”OFF” = warning ”BEEP“ off • After selecting the desired condition ( ON or OFF) press the switch (2) on the symbol (B) to confirm. The monitor will show “Value ON Saved” when enabling the audible warning or “Value OFF Saved” when disabling it. NOTE: If you want to stop the display, press the switch (2) on the symbol (A). This will automatically take you back to viewing the initial page ”BEEP ON/OFF”. Press the same symbol again to exit the programming menu.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Dynamic description setting units of measurement

DCAPLT5NE053S3A

If you want to change the unit of measurement, proceed as follows: • Press the switch (2) on the symbol (B) for more than three seconds to enter the programming menu The central monitor will show “SETUP MENU”. Release the symbol (B). • Press the switch (3) on the symbol (D) a number of consecutive times until the monitor shows ”MPH/km/h”. • Press the switch (2) on the symbol (B); the monitor will show the last setting made, ”MPH” or ”km/h”. Press the switch (3) on the symbol (D) or (C) to change the setting. • After selecting the desired unit of measurement, press the switch (2) on the symbol (B). The monitor will show “Value MPH Saved” or “Value km/h Saved” to confirm the selected unit of measurement. NOTE: If you want to stop the display, press the switch (2) on the symbol (A). This will automatically take you back to viewing the initial page ”MPH/km/h”. Press the same symbol again to exit the programming menu. NOTICE: This selection procedure changes all the units of measurement for the instrument panel, not just the speed.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Dynamic description of the DPF (Diesel Particulate Filter) regeneration A particulate filter (DPF) is a device designed to eliminate the polluting particulate produced by diesel engines from the exhaust gas; when it is blocked, it needs to be regenerated. The particulate filter can be regenerated automatically or by forcing. The start of the regeneration process is signalled to the operator on the dashboard's central monitor as well as by an acoustic signal. The indication is necessary for reasons of safety to warn the operator about the high exhaust temperature reached during the process.

CAUTION Burn hazard! During the Diesel Particulate Filter (DPF) regeneration process the exhaust stack and fixed hood area becomes extremely hot. Allow area to cool before servicing or working near the exhaust system components. Failure to comply could result in minor or moderate injury. C0102B

WARNING Fire hazard! During the Diesel Particulate Filter (DPF) forced regeneration process the exhaust stack and fixed hood area becomes extremely hot. Park the machine outside and away from combustible or highly flammable material. Failure to comply could result in death or serious injury. W1165B

NOTE: During the automatic regeneration process there may be a smell of burning or "overheating". The automatic regeneration does not affect engine performance. During the procedure, the operator can continue working normally. Under certain operating conditions automatic regeneration might not be completed (engine continuously stopping and starting, lengthy periods at idle speed) and it must then be repeated. The start of automatic regeneration, if set, is highlighted on the dashboard and he same symbol appears every 5 minutes on the central monitor with the word “ON” combined with a single beep. On concluding the operation the symbol appears with the word “OFF”. NOTICE: If, when requested, you do not proceed with manual or forced regeneration of the filter, its functionality will be impaired. If you continue to ignore this request, besides a considerable reduction in engine horsepower, the filter will be damaged to such an extent as to require it to be replaced by the dealer.

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Electrical systems - Warning indicators, alarms, and instruments

DPF to be regenerated Warning light on dashboard

Start with the control of forced regeneration

Flashing

OFF

Flashing

OFF

Flashing

OFF

Flashing

OFF

Central display

DPF to be regenerated Low severity

Warning light on dashboard

Automatic regeneration disabled, it is possible to start forced regeneration only Central display

DPF to be regenerated High severity

Warning light on dashboard

Automatic regeneration disabled, it is possible to start forced regeneration only Central display

DPF damaged Technical support required

Warning light on dashboard

Automatic and forced regeneration disabled Central display

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Electrical systems - Warning indicators, alarms, and instruments

Manual regeneration of the particulate filter DPF

MOIL12TRO0052

To be able, when necessary, to activate manual regeneration, it is necessary to stop work for the entire duration of the procedure ( 15 — 20 min) and set up the following conditions: • engine running, machine stationary and hand brake on • hand throttle at minimum position • foot throttle released • Power Take Off (PTO) not engaged • hydraulic system not active NOTE: should the above-mentioned conditions change during the entire process of regeneration, the operation is stopped. Proceed as follows to activate forced regeneration: • Press the switch (1) on the side of the symbol (B) for longer than three seconds to access the programming menu The central monitor will display “SETUP MENU”. Release the side with the symbol (B). • Press the switch (2) on the side of the symbol (D) for a certain number of consecutive times until the monitor displays the filter symbol (S1). • Press the switch (1) on the side with the symbol (B). • If manual filter regeneration is requested, the monitor will automatically display “START” with the filter symbol. • Press the switch (1) on the side of the symbol (B) to move on to the message “WAIT”. Filter regeneration now begins. In this phase, if everything proceeds normally, no action is required by the operator and the control unit will automatically display the various phases of the procedure. • At the end of regeneration the monitor will display “OFF” with the filter symbol. After two seconds the control unit will automatically return to the initial condition. Press the switch (1) on the side of the symbol (A) for a certain number of times until you exit the programming menu. NOTE: If during manual regeneration the operator modifies the conditions described above, or other conditions connected with the engine are not satisfactory, regeneration is stopped. The stop is signalled to the operator by the 47538922 29/05/2013

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Electrical systems - Warning indicators, alarms, and instruments

monitor displaying the filter symbol accompanied by the indication “FAIL” and a single acoustic signal. After 2 seconds, the control unit restores the condition present at the beginning of regeneration “START”. In this situation, after restoring the conditions prescribed for the operation, it is necessary to press the switch (1) on the side of the symbol (B) to restart the regeneration procedure.

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Electrical systems - Warning indicators, alarms, and instruments

Disabling automatic regeneration of the particulate filter DPF

MOIL12TR00911FA

If you want to disable or enable regeneration of the particulate filter, proceed as follows: • Press the switch (1) on the side of the symbol (B) for longer than three seconds to access the programming menu The central monitor will display “SETUP MENU”. Release the side with the symbol (B). • Press the switch (2) on the side of the symbol (D) for a certain number of consecutive times until the monitor displays the filter symbol S1. • Press the switch (1) on the side of the symbol (B) and the switch (2) on the side of the symbol (D) to display the screen S2, then press the button (B) • YES = automatic regeneration of the filter DISABLED • NO = automatic regeneration of the filter ENABLED • It is possible to change the setting by moving with the direction keys of the switch (2) on the symbols (C) and (D) to switch from “yes” to “no” and vice versa, then confirm by pressing the switch (1) on the side of the symbol (B). If automatic regeneration is disabled, the following warning light remains constantly illuminated on the dashboard and every 5 minutes the central monitor displays the following symbol together with a single acoustic signal (beep). If the system setting is suitable for the type of work to carry on, press the switch (1) on the side of the symbol (A) for a certain number of times until you exit the programming menu. NOTICE: It is always advised to keep the automatic regeneration function ENABLED.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Dynamic description oil change counter reset

DCAPLT5NE073S3F

NOTICE: Whenever changing oil it is indispensable to reset the engine oil working hours counter, as described below: NOTE: For this procedure the engine must be switched off. • Press the switch (2) on the symbol (B) for more than three seconds to enter the programming menu The central monitor will show “SETUP MENU”. Release the symbol (B). • Press the switch (3) on the symbol (D) a number of consecutive times until the monitor shows “OIL RESET” S1. • Press the switch (2) on the symbol (B) for the monitor to display “RESET”. • Press the switch (2) on the symbol (B) to reset the hour meter; the monitor will display “OFF”. • After two seconds the monitor automatically returns to the initial situation. Now press the switch (2) on the symbol (A) a number of times until you exit the programming menu. NOTE: If the hour meter has been reset correctly, the engine oil pressure warning on the instrument panel must blink for two seconds too.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Dynamic description fault codes display

DCAPLT5NE074S3F

If it is necessary to know the list of error codes or warnings saved by the control unit and not permanently visible, proceed as described below: • Press the switch (2) on the symbol (B) for more than three seconds to enter the programming menu The central monitor will show “SETUP MENU”. Release the symbol (B). • Press the switch (3) on the symbol (D) a number of consecutive times until the monitor shows the symbol for the error codes (S1). • Press the switch (2) on the symbol (B) to view the error codes in memory.. The error codes or warnings are displayed in two different ways: • At the top (2) of the monitor the symbol of the failed component appears combined with its error code at the bottom (1). System error symbols refer to an electrical or mechanical malfunction of the tractor's main components. May be accompanied by a four digit fault code. Stop work and call an authorized dealer. • The monitor will show only the symbol with no error code. When only the symbol is displayed, it is a warning. The advisory symbols are not detrimental to the operation of the tractor but should not be ignored. Take appropriate action where necessary. • Press the switch (1) on the symbol (A) to quit viewing error codes.. NOTE: The current fault codes are displayed in sequence. Each code is displayed three times blinking for 4 seconds.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Static description alarms The illumination of a warning light may be accompanied by an audible alarm. Depending on the severity of the malfunction, one of the following alarms may be heard.

Red indicator lamp Illumination of the red warning light (1) is normally associated with a critical alarm. Stop the tractor immediately when this warning light comes on. The warning light will stay on until the fault is corrected or the engine is switched off.

Amber indicator lamp DCAPLT5NE008S8A

Illumination of the amber warning light (2) is normally associated with a non-critical alarm. When this indicator light comes on, the operator can continue working. The fault should be rectified as soon as possible.

Action Required A two pulse alarm will sound for 1 second to advise the operator that a certain action is required. The alarm will continue to be displayed until the operator carries out the appropriate action or the tractor engine is switched off.

Safety and General Alarms A general continuous audible warning is emitted if the operator tries to perform inappropriate operations, for instance driving the tractor with the parking brake engaged.

Parking Lights A pulse alarm will sound for a short period if the engine is switched off and the parking lights are left on.

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Electrical systems - Warning indicators, alarms, and instruments

Warning and advisory symbols There are a number of warning/advisory symbols that may appear on the display (3). This display may be accompanied by the warning lights (1) or (2) coming on and by an audible warning, depending on the severity of the fault. The symbols can be categorised into four main groups. 1. Warning. These symbols advise of a fault that is critical to the operation of the tractor. Stop the tractor as soon as possible, investigate the cause and rectify the fault. 2. Maintenance. These symbols tell the operator there is a concern relating to the basic functions of the tractor, ie. water contamination in the fuel, alternator not charging etc. 3. System malfunction warning. The system fault symbols relate to an operational fault in one or more of the tractors main components, either electrical or mechanical. Maybe accompanied by a fault code. 4. Advisory. The advisory symbols are not detrimental to the operation of the tractor but should not be ignored. Take appropriate action where necessary.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Overview warnings on the display DISPLAY (DMD)

PANEL LAMP

WARNING LAMP

ALARM

Safety

CAUSE

CORRECTION

Operator leaves seat without Apply the hand brake; if it applying hand brake or if persists have the seat switch there is a fault with the seat checked. switch,

Correction

The maneuver performed is Operate the clutch pedal. incorrect or dangerous.

Correction

Hand brake engaged during Release the hand brake auto take-off. before auto take-off.

Correction Shuttle lever in drive.

Place shuttle lever in neutral.

Operate the tractor and wait Transmission oil temperature for the oil temperature to be too low. optimal. Immediately stop the engine Driveline oil pressure - too before it shuts down low. The tractor will be automatically, check the Critical stopped automatically in a level of oil in the transmission short time. and top it up if necessary. Immediately stop the engine before it shuts down automatically, and leave it to cool. Restart work and Driveline oil temperature too high. The tractor will be if the warning continues, Critical switch off the engine again, stopped automatically in a check the oil level of the short time. transmission, top it up if necessary and change the filter when needed. Immediately stop the engine Engine coolant temperature before it shuts down too high. The tractor will be automatically, and leave Critical it to cool. Make sure the stopped automatically in a radiator is clean and the fluid short time. is at the right level. Immediately stop the engine Engine oil pressure too low. before it shuts down The tractor will be stopped automatically, check the Critical automatically in a short time. level of engine oil and top it up if necessary. WARNING: Immediately stop Engine error state. The the engine before it shuts tractor will be stopped Critical down automatically, and automatically in a short time. contact your local dealer. The warning light will remain Rear power take−off lit until the operator returns to Safety engaged without the his seat or the power take−off operator. is disengaged. The warning light will remain Front power take−off lit until the operator returns to Safety engaged without the his seat or the power take−off operator. is disengaged. When battery voltage is Non Critical below 9 Volts for more than Recharge/renew the battery. 5 seconds. Correction

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Electrical systems - Warning indicators, alarms, and instruments

DISPLAY (DMD)

PANEL LAMP

WARNING LAMP

ALARM

CAUSE

Critical

Driveline/Steering oil pressure too low

Critical

Engine coolant temperature too high

Critical

Engine oil pressure too low.

Safety

Handbrake engaged during driving

Release hand brake. Low warning only. Keep an eye on this warning

Critical

Stop the engine immediately and let it cool down. If the warning continues, switch off the engine again, check the oil level of the transmission, top it up if necessary and change the filter when needed.

Driveline Oil Temperature Too High

Critical

Stop the tractor as soon as possible, check the oil level and top up if necessary. Contact an authorised dealer if the failure persists. Immediately stop the tractor leaving the engine running for a few minutes. If the warning persists, stop the engine and check that the radiator is clean and that the fluid level is correct. Stop the machine, check the oil level and top up if necessary.

Non Critical

CORRECTION

No regeneration of the diesel Follow the directions for the particulate filter (DPF). error code.

Operation of the power take−off is prevented for a few seconds. After this time, the operator can re-engage the power take−off. Operation of the power PTO system anti-stall. The take−off is prevented for a Non Critical anti-stall function disengages few seconds. After this time, the power take−off. the operator can re-engage the power take−off. Internal and external Non Critical push-buttons activated simultaneously.

Non Critical Exhaust system failure.

Non Critical

Critical

Monitor the warning.

Exhaust system failure. If the warning continues, Engine power loss occurring. contact your Dealer. Persistence of the fault on the diesel particulate filter (DPF). Engine power loss occurring.

If the warning continues, contact your Dealer.

Engine Intake Air Filter Blocked

Clean the filtering cartridges as described in the maintenance section.

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Electrical systems - Warning indicators, alarms, and instruments

DISPLAY (DMD)

PANEL LAMP

WARNING LAMP

ON -

OFF

Battery voltage too high.

Module configuration. This warning light comes on when Non Critical a new module is added, with the starter key ON.

CAUSE

CORRECTION

If the warning light fails to go out a few seconds after Have your dealer check the starting, it means that the system. alternator is not charging the battery. Top up the brake fluid level and check the level sensor works properly as described in the maintenance section. Brake fluid level too low. If the signal continues, have your dealer check the system. Clean the filter as described in the maintenance section. Start the engine and if the Non Critical Water in fuel. signal stays on, have your dealer check the system. Carry out the programmed Request for "light" type of maintenance at the maintenance scheduled time. Carry out the programmed Request for "heavy duty" type of maintenance at the maintenance scheduled time.

ALARM

Module Configured

Request for regeneration of Non Critical the diesel particulate filter (DPF). Automatic regeneration on. It lights up when automatic regeneration of the diesel particulate filter is started. Single beep It lights up when automatic regeneration of the diesel particulate filter has ended.

Call your local dealer. Turn the key (OFF) all off, turn the key (ON) onto the first click. If the configuration has been done correctly the display will show the next symbol.. The instrument panel gives a visual warning of the new module. Proceed with the automatic regeneration of the diesel particulate filter. It is possible to continue working during the procedure of filter regeneration.

At the end of the procedure the icon goes out and the display returns to its normal functions. Stop the tractor and proceed with forced regeneration of Request for forced the diesel particulate filter regeneration of the diesel (DPF) as described in this particulate filter (DPF). manual. Single beep Automatic regeneration was NOTE: During forced prevented by the operator. regeneration it is not possible Reminder every 5 minutes. to move the machine. Enable automatic regeneration as soon as possible. To avoid damage, change Non Critical Engine oil change warning. it when required; see maintenance section. 47538922 29/05/2013

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Electrical systems - Warning indicators, alarms, and instruments

DISPLAY (DMD)

PANEL LAMP -

WARNING LAMP -

ALARM

CAUSE

CORRECTION

Battery cut-off request. The Automatic battery cut-off warning appears for a time of when the engine is shut 60 seconds when the engine down. is shut down. Reduce the towing force on the tractor or on the Exceeding the wheel slip implement. the warning Non Critical limit. (only if the radar unit is persists. until the slip present) percentage comes back within the permissible range. Turn off the direction Non Critical Direction indicators indicators after completing the manoeuvre.

Non Critical

Handbrake not applied. The signal is only made with the Engage the hand brake. Non Critical starter key OFF and the hand brake is not engaged.

Position lights on with starter Switch off the side lights. key OFF.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Dynamic description setting hours worked Setting hours counter on a new Analog Digital Instrument Cluster (ADIC) 1 . Turn the ignition switch ((1) , 2) onto (A) (OFF) and connect the implement 380000843 (2) to the relevant diagnostics socket (1) , after taking off the protective cap.

WLAPL4S55C108A

WLAPL4S55C110A

2 . Press and hold down the ENTER button ( (1) , 3 ) while turning the key (1) onto power.

3 . The display will show the " HH MENU " icon, (see 4 ).

WLAPL4S55C1007A

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Electrical systems - Warning indicators, alarms, and instruments

WLAPL4S55C101G

4 . Press and hold down the ENTER button ( (1) , 3 ), after 5 s , the display will show the number of hours worked if it is not already shown. 5 . Hold down the ENTER button ( (1) , 3) for longer than 5 s but less than 12 s, now the number of hours worked will blink. 6 . In this case we can proceed in two different ways: (A) - Press the HOME button ( (1) , 3 ) to end the operation without changing the value and go back to the " HH MENU " screen: (B) - Use the UP button ( (2) , 3 ) to increase the number of hours, afterwards press the ENTER button ( (1) , 3) for 15 s to save and exit the " HH MENU" screen.

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Index Electrical systems - 55 Warning indicators, alarms, and instruments - 408 Instrument cluster - Dynamic description (ADIC) programmable display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Instrument cluster - Dynamic description Speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Instrument cluster - Dynamic description audible warning on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Instrument cluster - Dynamic description dashboard/display brightness adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 7 Instrument cluster - Dynamic description display information and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Instrument cluster - Dynamic description fault codes display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Instrument cluster - Dynamic description implement width calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Instrument cluster - Dynamic description of the DPF (Diesel Particulate Filter) regeneration . . . . . . . . . . . . . . . . . 16 Instrument cluster - Dynamic description oil change counter reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Instrument cluster - Dynamic description programming maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Instrument cluster - Dynamic description setting hours worked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Instrument cluster - Dynamic description setting units of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Instrument cluster - Overview warnings on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Instrument cluster - Static description alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Electrical systems - 55 FAULT CODES - DTC

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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Contents Electrical systems - 55 FAULT CODES - DTC

DIAGNOSTIC 1008-Raise/work switch failure (command arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2005-Creeper engage fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2013-Upshift and downshift switch ON error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2027-Engine speed no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 3293-Fuel Metering Unit: maximum positive deviation of rail pressure exceeded . . . . . . . . . . . . . . . . . . . 20 3796-Diesel particulate filter pressure sensor hose line error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4564-EHR joystick - no communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 CH-HOT OIL WARNING: displayed above 105 degress C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 CL-COLD OIL WARNING: displayed below 60 degrees C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 U147-Synchroniser cannot be engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 U148-Range lever not in the high range position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 U17-Seat switch not activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 U19-Oil temperature below 10Â°C, calibration not allowed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 U20-Handbrake is not set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 U21-ERPM is below 1050, increase throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 U22-ERPM is above 1350, reduce throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 U23-Shuttle lever is in neutral, shift lever to forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 U26-Clutch pedal is not up, release clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 U27-C3 calibration value is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 U29-C4 calibration value is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 U31-Wheel speed sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 U32-C1 calibration value is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 U34-C2 calibration value is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 U36-Max allowed clutch calibration value exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 U37-Synchroniser potentiometer signal is out of range for the reverse position . . . . . . . . . . . . . . . . . . . . 41 U38-Synchroniser potentiometer signal is out of range for the forward position . . . . . . . . . . . . . . . . . . . . 42 U39-Synchroniser did not move toward reverse, even at maximum pressure . . . . . . . . . . . . . . . . . . . . . . 43 U40-Synchroniser did not move toward forward, even at maximum pressure . . . . . . . . . . . . . . . . . . . . . . 44 U41-Synchroniser pot signal is out of range for the 4 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 U42-Synchroniser pot signal is out of range for the 5 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 U43-Synchroniser did not move toward 4, even at max pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 U44-Synchroniser did not move toward 5, even at max pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 47538922 29/05/2013

55.8 [55.DTC] / 2

U82-No 12VD: no power for C3 and C4 solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 [ADIC] - 14015-5V reference voltage - too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 [ADIC] - 14016-5V reference voltage - too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 [ADIC] - 14021-Cranking line - shorted to +12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 [ADIC] - 14022-Cranking line - shorted to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 [ADIC] - 14051-Fuel level sensor - short circuit to supply voltage or open circuit . . . . . . . . . . . . . . . . . . . 58 [ADIC] - 14052-Fuel level sensor - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 [ADIC] - 14058-Seat switch closed over 25 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 [ADIC] - 14061-Air brake pressure short to Vcc or option set but sensor not connected . . . . . . . . . . . . . 64 [ADIC] - 14093-Seat switch signal short to + 12V or open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 [ADIC] - 14094-Seat switch - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 [ADIC] - 14100-Air brake option not configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 [ADIC] - 14200-Battery isolator switch closed to battery at Key ON for more than 30 seconds . . . . . . . 72 [ADIC] - 14900-CCU module missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 [ADIC] - 14901-Engine controller missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 [ADIC] - 14908-TECU module missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 [CCU] - 1002-Radar sensor - disconnected or speed too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 [CCU] - 1003-Radar sensor and transmission output speed sensor - speed difference too high . . . . . . 83 [CCU] - 1004-Transmission output speed sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 [CCU] - 1006-Hitch slip control potentiometer - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 [CCU] - 1007-Hitch slip control potentiometer - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 [CCU] - 1009-Hitch position control switches - implausible signals or signal at key on . . . . . . . . . . . . . . 89 [CCU] - 1010-Hitch height limit potentiometer - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 [CCU] - 1011-Hitch height limit potentiometer - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 [CCU] - 1012-Hitch drop rate potentiometer - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 [CCU] - 1013-Hitch drop rate potentiometer - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 [CCU] - 1014-Right-hand draft pin sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 [CCU] - 1015-Right-hand draft pin sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 [CCU] - 1016-Left-hand draft pin sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 [CCU] - 1017-Left-hand draft pin sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 [CCU] - 1018-Draft pin sensors - both signals too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 [CCU] - 1019-8 V reference voltage for draft pin sensors - voltage too low . . . . . . . . . . . . . . . . . . . . . . . 110 [CCU] - 1020-8 V reference voltage for draft pin sensors - voltage too high . . . . . . . . . . . . . . . . . . . . . . 112 [CCU] - 1021-Hitch sensitivity control potentiometer - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 [CCU] - 1022-Hitch sensitivity control potentiometer - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 [CCU] - 1023-Hitch electronic control panel - disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 [CCU] - 1024-Hitch position sensor - not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 [CCU] - 1025-Hitch position control potentiometer - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 [CCU] - 1026-Hitch position control potentiometer - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 [CCU] - 1027-Hitch position sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 [CCU] - 1028-Hitch position sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 [CCU] - 1029-Hitch control solenoid valves - disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 [CCU] - 1030-Hitch electronic control panel - ground disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 47538922 29/05/2013

55.8 [55.DTC] / 3

[CCU] - 1031-Chassis harness - disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 [CCU] - 1032-Hitch draft control potentiometer - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 [CCU] - 1033-Hitch draft control potentiometer - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 [CCU] - 1049-CAN-Bus signal fault - transmission output speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 [CCU] - 1053-5 V reference voltage for Electronic Draft Control (EDC) - voltage too high . . . . . . . . . . 142 [CCU] - 1054-5 V reference voltage for Electronic Draft Control (EDC) - voltage too low . . . . . . . . . . . 144 [CCU] - 1063-Lower solenoid valve - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 [CCU] - 1064-Raise solenoid valve - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 [CCU] - 1065-Lower solenoid valve - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 [CCU] - 1066-Raise solenoid valve - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 [CCU] - 1067-Supply voltage for hitch control solenoid valves - voltage too low . . . . . . . . . . . . . . . . . . . 154 [CCU] - 1068-Electronic Draft Control (EDC) - calibration fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 [CCU] - 1070-Electronic Draft Control (EDC) - ram configuration not set . . . . . . . . . . . . . . . . . . . . . . . . . 157 [CCU] - 2001-Shuttle too fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 [CCU] - 2006-Radar sensor - disconnected or speed too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 [CCU] - 2011-Clutch pedal sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 [CCU] - 2012-Clutch pedal sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 [CCU] - 2016-Creeper solenoid error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 [CCU] - 2024-At least one synchroniser require calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 [CCU] - 2026-Engine speed - too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 [CCU] - 2037-Clutch pedal switch - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 [CCU] - 2038-Clutch 4 solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 [CCU] - 2039-Clutch 4 solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 [CCU] - 2040-Clutch 3 solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 [CCU] - 2041-Clutch 3 solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 [CCU] - 2042-Clutch 2 solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 [CCU] - 2043-Clutch 2 solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 [CCU] - 2044-Clutch 1 solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 [CCU] - 2045-Clutch 1 solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 [CCU] - 2047-Clutch pedal switch set too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 [CCU] - 2048-Clutch pedal switch set too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 [CCU] - 2049-Wheel speed sensor - short to ground or open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 [CCU] - 2050-Transmission output speed sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 [CCU] - 2051-Transmission oil temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 [CCU] - 2052-Transmission oil temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 [CCU] - 2053-5V reference voltage - voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 [CCU] - 2054-5V reference voltage - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 [CCU] - 2055-Transmission output speed sensor - implausible speed drop detected . . . . . . . . . . . . . . . 206 [CCU] - 2056-Low Range switch open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 [CCU] - 2057-High Range switch open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 [CCU] - 2059-Shuttle lever - implausible signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 [CCU] - 2061-Forward/reverse synchroniser potentiometer signal too high . . . . . . . . . . . . . . . . . . . . . . . 214 [CCU] - 2062-Forward/reverse synchroniser potentiometer signal too low . . . . . . . . . . . . . . . . . . . . . . . . 217 47538922 29/05/2013

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[CCU] - 2063-Forward synchroniser did not engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 [CCU] - 2064-Reverse synchroniser did not engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 [CCU] - 2065-Forward synchroniser solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 [CCU] - 2066-Reverse synchroniser solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 [CCU] - 2067-Forward synchroniser solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 [CCU] - 2068-Reverse synchroniser solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 [CCU] - 2070-Shuttle lever forward switch - voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 [CCU] - 2071-Shuttle lever forward switch - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 [CCU] - 2072-Shuttle lever reverse switch - voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 [CCU] - 2073-Shuttle lever reverse switch - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 [CCU] - 2081-4/5 range synchroniser potentiometer - signal high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 [CCU] - 2082-4/5 range synchroniser potentiometer - signal low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 [CCU] - 2083-1-4 range synchroniser engaged error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 [CCU] - 2084-5-8 range synchroniser engaged error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 [CCU] - 2085-1-4 range synchroniser solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 [CCU] - 2086-5-8 range synchroniser solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 [CCU] - 2087-1-4 range synchroniser solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 [CCU] - 2088-5-8 range synchroniser solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 [CCU] - 2089-CAN-Bus - invalid engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 [CCU] - 2090-CAN-Bus - ADIC absent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 [CCU] - 2091-Clutch 3 not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 [CCU] - 2092-Clutch 4 not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 [CCU] - 2095-Clutch 1 not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 [CCU] - 2096-Clutch 2 not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 [CCU] - 2110-Voltage from Shuttle lever Neutral switch too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 [CCU] - 2111-Voltage from Shuttle lever Neutral switch too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 [CCU] - 4500-Electro Hydraulic Remote valve (EHR) front 1 - no control message received . . . . . . . . 266 [CCU] - 4501-Electro Hydraulic Remote valve (EHR) front 1 - control message not plausible . . . . . . . 268 [CCU] - 4502-Electro Hydraulic Remote valve (EHR) front 1 - EEPROM fault . . . . . . . . . . . . . . . . . . . . . 270 [CCU] - 4503-Electro Hydraulic Remote valve (EHR) front 1 - switched to failsafe . . . . . . . . . . . . . . . . . 271 [CCU] - 4504-Electro Hydraulic Remote valve (EHR) front 1 - under-voltage . . . . . . . . . . . . . . . . . . . . . 272 [CCU] - 4505-Electro Hydraulic Remote valve (EHR) front 1 - over-voltage . . . . . . . . . . . . . . . . . . . . . . . 274 [CCU] - 4506-Electro Hydraulic Remote valve (EHR) front 1 - spool movement too low . . . . . . . . . . . . 275 [CCU] - 4507-Electro Hydraulic Remote valve (EHR) front 1 - spool movement too high . . . . . . . . . . . 276 [CCU] - 4508-Electro Hydraulic Remote valve (EHR) front 1 - float position not reached . . . . . . . . . . . 277 [CCU] - 4509-Electro Hydraulic Remote valve (EHR) front 1 - manually operated . . . . . . . . . . . . . . . . . 278 [CCU] - 4511-Electro Hydraulic Remote valve (EHR) front 1 - potentiometer faulty . . . . . . . . . . . . . . . . 279 [CCU] - 4512-Electro Hydraulic Remote valve (EHR) front 1 - unable to reach neutral . . . . . . . . . . . . . 280 [CCU] - 4513-Electro Hydraulic Remote valve (EHR) front 1 - spool not in neutral at key on . . . . . . . . 281 [CCU] - 4514-Electro Hydraulic Remote valve (EHR) front 2 - no control message received . . . . . . . . 282 [CCU] - 4515-Electro Hydraulic Remote valve (EHR) front 2 - control message not plausible . . . . . . . 284 [CCU] - 4516-Electro Hydraulic Remote valve (EHR) front 2 - EEPROM fault . . . . . . . . . . . . . . . . . . . . . 286 [CCU] - 4517-Electro Hydraulic Remote valve (EHR) front 2 - switched to failsafe . . . . . . . . . . . . . . . . . 287 47538922 29/05/2013

55.8 [55.DTC] / 5

[CCU] - 4518-Electro Hydraulic Remote valve (EHR) front 2 - under-voltage . . . . . . . . . . . . . . . . . . . . . 288 [CCU] - 4519-Electro Hydraulic Remote valve (EHR) front 2 - over-voltage . . . . . . . . . . . . . . . . . . . . . . . 290 [CCU] - 4520-Electro Hydraulic Remote valve (EHR) front 2 - spool movement too low . . . . . . . . . . . . 291 [CCU] - 4521-Electro Hydraulic Remote valve (EHR) front 2 - spool movement too high . . . . . . . . . . . 292 [CCU] - 4522-Electro Hydraulic Remote valve (EHR) front 2 - float position not reached . . . . . . . . . . . 293 [CCU] - 4523-Electro Hydraulic Remote valve (EHR) front 2 - manually operated . . . . . . . . . . . . . . . . . 294 [CCU] - 4525-Electro Hydraulic Remote valve (EHR) front 2 - potentiometer faulty . . . . . . . . . . . . . . . . 295 [CCU] - 4526-Electro Hydraulic Remote valve (EHR) front 2 - unable to reach neutral . . . . . . . . . . . . . 296 [CCU] - 4527-Electro Hydraulic Remote valve (EHR) front 2 - spool not in neutral at key on . . . . . . . . 297 [CCU] - 5001-Rear PTO brake solenoid error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 [CCU] - 5005-Rear PTO brake switch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 [CCU] - 5008-Rear PTO clutch solenoid - open circuit error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 [CCU] - 5027-Rear PTO speed sensor - open circuit error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 [CCU] - 5033-Rear PTO cab normally closed switch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 [CCU] - 5034-Rear PTO fender switch - open circuit / short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 [CCU] - 5035-Rear PTO fender switch - input short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 [CCU] - 5037-Rear PTO cab switch normally open error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 [CCU] - 5043-Rear PTO fender switch stuck on error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 [CCU] - 5044-Rear PTO speed sensor - short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 [CCU] - 5045-Ground speed PTO switch open / short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 [CCU] - 5046-Ground speed PTO switch short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 [CCU] - 5047-Ground speed PTO configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 [CCU] - 5098-Rear PTO fender switch option not enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 [CCU] - 5099-Rear PTO Auto PTO not enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 [CCU] - 6020-FWD (four wheel drive) command switch fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 [CCU] - 6023-FWD solenoid short to ground or open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 [CCU] - 7014-Differential lock command switch error - switch disconnected . . . . . . . . . . . . . . . . . . . . . . 334 [CCU] - 7017-Differential lock short to ground or open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 [CCU] - 8008-Front PTO solenoid - open circuit or short to VBat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 [CCU] - 8033-Front PTO cab normally closed switch - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 [CCU] - 8037-Front PTO cab normally open switch - stuck closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 [CCU] - 8099-Front PTO option not enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 [ECU] - 3001-Foot throttle position sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 [ECU] - 3002-Foot throttle position sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 [ECU] - 3003-Foot throttle position sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 [ECU] - 3007-Engine coolant temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 [ECU] - 3008-Engine coolant temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 [ECU] - 3010-Intake air pressure and temperature sensor - temperature signal too high . . . . . . . . . . . 360 [ECU] - 3011-Intake air pressure and temperature sensor - temperature signal too low . . . . . . . . . . . . 364 [ECU] - 3015-Fuel temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368 [ECU] - 3016-Fuel temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 [ECU] - 3019-Intake air pressure and temperature sensor - pressure signal too high . . . . . . . . . . . . . . 373 [ECU] - 3024-Air pressure sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376 47538922 29/05/2013

55.8 [55.DTC] / 6

[ECU] - 3025-Air pressure sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377 [ECU] - 3027-Engine oil pressure switch - defect fault check for plausibility . . . . . . . . . . . . . . . . . . . . . . 378 [ECU] - 3037-Boost pressure sensor - signal low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 [ECU] - 3038-Constant engine speed selector switch - signals not plausible . . . . . . . . . . . . . . . . . . . . . . 384 [ECU] - 3052-ECU supply voltage - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 [ECU] - 3059-Main relay ECU - stuck relay fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 [ECU] - 3063-Injector cylinder 1 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 [ECU] - 3071-Injector cylinder 3 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393 [ECU] - 3079-Injector cylinder 2 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396 [ECU] - 3083-Injector cylinder 4 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399 [ECU] - 3088-Crankshaft sensor - no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402 [ECU] - 3089-Crankshaft sensor - invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406 [ECU] - 3090-Camshaft sensor - no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 [ECU] - 3091-Camshaft sensor - invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412 [ECU] - 3093-Crankshaft sensor and camshaft sensor - offset between speed signals too high . . . . . 415 [ECU] - 3096-CAN-Bus - ECU in bus-off state or CAN-Bus fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 [ECU] - 3102-Common rail pressure sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 [ECU] - 3104-Common rail relief valve - open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 [ECU] - 3106-Pressure relief valve reached maximum allowed opening count . . . . . . . . . . . . . . . . . . . . 423 [ECU] - 3107-High pressure pump solenoid valve - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . 424 [ECU] - 3108-High pressure pump solenoid valve - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . 426 [ECU] - 3112-Common rail pressure sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 [ECU] - 3126-Hand throttle - signal 1 too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430 [ECU] - 3127-Hand throttle - signal 1 too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432 [ECU] - 3137-High pressure pump solenoid valve - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 [ECU] - 3139-High pressure pump solenoid valve - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 [ECU] - 3140-High pressure pump solenoid valve - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438 [ECU] - 3146-Water in fuel sensor - water detected or faulty sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 [ECU] - 3157-CAN-Bus - ECU absent or engine dataset not available . . . . . . . . . . . . . . . . . . . . . . . . . . . 442 [ECU] - 3166-Fuel heater relay - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 [ECU] - 3167-Fuel heater relay - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446 [ECU] - 3168-Fuel heater relay - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448 [ECU] - 3169-Fuel heater relay - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 [ECU] - 3179-CAN-Bus message timeout - BC2EDC2 from ADIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452 [ECU] - 3180-CAN-Bus message timeout - VCM2EDC from ADIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 [ECU] - 3188-Injector cylinder 1 - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456 [ECU] - 3192-Injector cylinder 2 - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459 [ECU] - 3196-Injector cylinder 3 - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462 [ECU] - 3200-Injector cylinder 4 - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465 [ECU] - 3210-Injection bank 1 - short circuit on injection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468 [ECU] - 3218-Injection bank 2 - short circuit on injection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472 [ECU] - 3283-Sensor supply voltage 2 - voltage out of valid range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476 [ECU] - 3285-Sensor supply voltage 3 - voltage out of valid range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478 47538922 29/05/2013

55.8 [55.DTC] / 7

[ECU] - 3301-High pressure pump solenoid valve - maximum negative rail pressure deviation exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480 [ECU] - 3309-High pressure pump solenoid valve - maximum rail pressure exceeded . . . . . . . . . . . . . 481 [ECU] - 3334-CAN-Bus message timeout - TSC1-PE from CCU (when active) . . . . . . . . . . . . . . . . . . . 482 [ECU] - 3335-CAN-Bus message timeout - TSC1-PE from CCU (when inactive) . . . . . . . . . . . . . . . . . . 484 [ECU] - 3338-CAN-Bus message timeout - TSC1-VE from CCU (when inactive) . . . . . . . . . . . . . . . . . . 486 [ECU] - 3339-CAN-Bus message timeout - TSC1-VE from CCU (when active) . . . . . . . . . . . . . . . . . . . 488 [ECU] - 3358-CAN-Bus message timeout - transmit EEC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 [ECU] - 3375-Constant engine speed increase/decrease switch - signals not plausible . . . . . . . . . . . . 492 [ECU] - 3377-CRPM switches present but function not enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495 [ECU] - 3402-Rail pressure sensor: Maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . 496 [ECU] - 3405-Turbocharger power stage - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497 [ECU] - 3406-Turbocharger power stage - temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 [ECU] - 3408-Lambda sensor - oxygen concentration too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503 [ECU] - 3409-Engine oil pressure switch - oil pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506 [ECU] - 3410-Throttle Valve Actuator (TVA) - positive position deviation limit exceeded . . . . . . . . . . . . 509 [ECU] - 3411-Throttle Valve Actuator (TVA) - negative position deviation limit exceeded . . . . . . . . . . . 511 [ECU] - 3414-Glow plug of cylinder 1 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 [ECU] - 3415-Glow plug of cylinder 3 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515 [ECU] - 3416-Glow plug of cylinder 4 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517 [ECU] - 3417-Glow plug of cylinder 2 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519 [ECU] - 3418-Turbocharger power stage - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 [ECU] - 3419-Turbocharger power stage - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524 [ECU] - 3425-Turbocharger - boost pressure deviation too high at intake air pressure and temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527 [ECU] - 3426-Diesel Particulate Filter (DPF) - level 1 reached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528 [ECU] - 3428-Differential pressure sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529 [ECU] - 3432-Exhaust Gas Recirculation (EGR) - inducement warning . . . . . . . . . . . . . . . . . . . . . . . . . . 531 [ECU] - 3435-Diesel Particulate Filter (DPF) - inducement warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532 [ECU] - 3517-Inlet air temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533 [ECU] - 3518-Inlet air temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535 [ECU] - 3648-Turbocharger - boost pressure deviation too high at intake air pressure and temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537 [ECU] - 3650-Battery voltage - voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538 [ECU] - 3651-Battery voltage - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 [ECU] - 3652-CAN-Bus - bus-off state of node A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542 [ECU] - 3657-CAN-Bus message timeout - CM1BC from ADIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544 [ECU] - 3663-Exhaust Gas Recirculation (EGR) - command saturation over higher limit . . . . . . . . . . . 546 [ECU] - 3664-Exhaust Gas Recirculation (EGR) - command saturation over lower limit . . . . . . . . . . . . 548 [ECU] - 3665-Exhaust Gas Recirculation (EGR) valve actuator - positive position deviation limit exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 [ECU] - 3666-Exhaust Gas Recirculation (EGR) valve actuator - negative position deviation limit exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552 [ECU] - 3667-Exhaust Gas Recirculation (EGR) valve actuator - open circuit at power stage . . . . . . . 554

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[ECU] - 3668-Exhaust Gas Recirculation (EGR) valve actuator - over-temperature at power stage . . 557 [ECU] - 3669-Exhaust Gas Recirculation (EGR) valve actuator - short circuit to battery on Out1 of power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560 [ECU] - 3670-Exhaust Gas Recirculation (EGR) valve actuator - short circuit to battery on Out2 of power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562 [ECU] - 3671-Exhaust Gas Recirculation (EGR) valve actuator - short circuit to ground on Out1 of power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564 [ECU] - 3672-Exhaust Gas Recirculation (EGR) valve actuator - short circuit to ground on Out2 of power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567 [ECU] - 3673-Exhaust Gas Recirculation (EGR) valve actuator - short circuit at power stage . . . . . . . 570 [ECU] - 3674-Exhaust Gas Recirculation (EGR) valve actuator - under-voltage at power stage . . . . . 573 [ECU] - 3675-Long time EGR valve drift at closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574 [ECU] - 3676-Exhaust Gas Recirculation (EGR) valve actuator - position sensor voltage too high . . . 575 [ECU] - 3677-Exhaust Gas Recirculation (EGR) valve actuator - position sensor voltage too low . . . . 578 [ECU] - 3688-Water in fuel sensor - water in fuel detected or defective sensor . . . . . . . . . . . . . . . . . . . . 581 [ECU] - 3689-Glow plug control module - faulty diagnostic data transmission or protocol fault . . . . . . 583 [ECU] - 3691-Glow plug control module - open circuit at power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . 586 [ECU] - 3692-Glow plug control module - over-temperature at power stage . . . . . . . . . . . . . . . . . . . . . . 588 [ECU] - 3693-Glow plug control module - short circuit to battery at power stage . . . . . . . . . . . . . . . . . . . 591 [ECU] - 3694-Glow plug control module - short circuit to ground at power stage . . . . . . . . . . . . . . . . . . 594 [ECU] - 3707-Lambda sensor - open circuit at the nernst cell pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597 [ECU] - 3708-Lambda sensor - open circuit at the pump current pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 [ECU] - 3709-Lambda sensor - open circuit at the virtual ground pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603 [ECU] - 3710-Lambda sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606 [ECU] - 3711-Lambda sensor - short circuit to battery at heater power stage . . . . . . . . . . . . . . . . . . . . . 609 [ECU] - 3712-Lambda sensor - short circuit to ground at heater power stage . . . . . . . . . . . . . . . . . . . . . 612 [ECU] - 3713-Lambda sensor: Open load error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . 615 [ECU] - 3713-Lambda sensor - open circuit at heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617 [ECU] - 3714-Lambda sensor - oxygen ratio signal too high during calibration . . . . . . . . . . . . . . . . . . . . 619 [ECU] - 3715-Lambda sensor - oxygen ratio signal too low during calibration . . . . . . . . . . . . . . . . . . . . . 622 [ECU] - 3716-Lambda sensor - oxygen ratio signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625 [ECU] - 3720-Lambda sensor - supply voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627 [ECU] - 3722-Lambda sensor - calculated temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629 [ECU] - 3723-Lambda sensor - calculated temperature too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631 [ECU] - 3724-Lambda sensor - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633 [ECU] - 3725-Lambda sensor - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635 [ECU] - 3735-High pressure pump metering solenoid valve - over-temperature . . . . . . . . . . . . . . . . . . . 637 [ECU] - 3736-Lambda sensor - oxygen ratio out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639 [ECU] - 3737-Lambda sensor - over-temperature at heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . 640 [ECU] - 3762-Level 2 monitoring - sensor supply voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642 [ECU] - 3763-Level 2 monitoring - sensor supply voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644 [ECU] - 3764-Main relay ECU - early opening fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646 [ECU] - 3790-Diesel Particulate Filter (DPF) - flow resistance exceeded maximum limit . . . . . . . . . . . . 649 [ECU] - 3794-Intake air pressure and temperature sensor - signal not plausible . . . . . . . . . . . . . . . . . . . 652

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[ECU] - 3795-Intake air pressure and temperature sensor - signal not plausible . . . . . . . . . . . . . . . . . . . 655 [ECU] - 3797-Differential pressure sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658 [ECU] - 3798-Differential pressure sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661 [ECU] - 3801-Exhaust manifold pressure sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664 [ECU] - 3802-Exhaust manifold pressure sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667 [ECU] - 3810-Common rail pressure sensor - intermittent signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 670 [ECU] - 3818-Throttle Valve Actuator (TVA) - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 672 [ECU] - 3819-Throttle Valve Actuator (TVA) - over-current at power stage . . . . . . . . . . . . . . . . . . . . . . . . 675 [ECU] - 3820-Throttle Valve Actuator (TVA) - over-temperature at power stage . . . . . . . . . . . . . . . . . . . 678 [ECU] - 3821-Throttle Valve Actuator (TVA) - short circuit to battery at Out1 of power stage . . . . . . . . 681 [ECU] - 3822-Throttle Valve Actuator (TVA) - short circuit to battery at Out2 of power stage . . . . . . . . 683 [ECU] - 3823-Throttle Valve Actuator (TVA) - short circuit to ground at Out1 of power stage . . . . . . . . 685 [ECU] - 3824-Throttle Valve Actuator (TVA) - short circuit to ground at Out2 of power stage . . . . . . . . 688 [ECU] - 3825-Throttle Valve Actuator (TVA) - short circuit at power stage . . . . . . . . . . . . . . . . . . . . . . . . 691 [ECU] - 3826-Throttle Valve Actuator (TVA) - temperature dependent over-current at power stage . . 694 [ECU] - 3827-Throttle Valve Actuator (TVA) - under-voltage at power stage . . . . . . . . . . . . . . . . . . . . . . 697 [ECU] - 3830-Throttle Valve Actuator (TVA) - position signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698 [ECU] - 3831-Throttle Valve Actuator (TVA) - position signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 [ECU] - 3834-Throttle Valve Actuator (TVA) - position signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702 [ECU] - 3835-Throttle Valve Actuator (TVA) - position signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704 [ECU] - 3838-Diesel Oxidation Catalyst (DOC) inlet temperature sensor - signal too high . . . . . . . . . . 706 [ECU] - 3839-Diesel Oxidation Catalyst (DOC) inlet temperature sensor - signal too low . . . . . . . . . . . 709 [ECU] - 3840-Diesel Particulate Filter (DPF) inlet temperature sensor - signal too high . . . . . . . . . . . . 711 [ECU] - 3841-Diesel Particulate Filter (DPF) inlet temperature sensor - signal too low . . . . . . . . . . . . . 714 [ECU] - 3842-Exhaust manifold temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716 [ECU] - 3843-Exhaust manifold temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719 [ECU] - 3852-Lambda sensor - insufficient heater performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722 [ECU] - 3870-CAN-Bus message timeout - BC2EDC1 from ADIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 [ECU] - 3899-Info: Engine temperature exceeded pre-warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 T5.

[ECU] - 3900-Info: Engine temperature exceeded warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 [ECU] - 3910-High pressure pump solenoid valve - intermittent connection to ECU . . . . . . . . . . . . . . . . 727

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1008-Raise/work switch failure (command arm) Possible failure modes: 1. Faulty connector 2. Faulty raise/work switch 3. Wiring harness faulty 4. Faulty controller Solution: 1.

Check the raise/work switch in H5. A. The display will show d_ _. Move the fast raise/work switch between the raise and work positions several times, and check the display. If the display does not change, continue to step 8 B. If the display passes from d_ _ to d4, d5 and then d6, the switch and the circuit are okay. If the display shows d_ _ and d4 then d6, continue to step 2 C. If the display shows d_ _ and d5 then d6, continue to step 5

Check the raise/work switch. A. Disconnect the connector X-326 of the lift/work switch. With the switch in the raise position, check between the connector: X-326 pin F and the connector X-326 pin E X-326 pin F and the connector X-326 pin H. If an open circuit is indicated, replace the raise/work switch. B. If the raise/work switch is okay, continue to step 3

Check for an open circuit. A. Disconnect the connectors X-210 and X-230 of the controller. Check between the connector: X-326 pin E wire 0.5 (BR/WH) and X-210 pin 20 wire 0.5 (BR/WH) X-326 pin H wire 0.5 (TQ) and X-230 pin 6 wire 0.5 (TQ). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicate, continue to step 4

Check for a short circuit or a short to ground. A. Check between: X-326 pin E wire 0.5 (BR/WH) and X-326 pin F wire 0.5 (BK/YE) X-326 pin E wire 0.5 (BR/WH) and ground X-326 pin F wire 0.5 (BK/YE) and ground X-326 pin H wire 0.5 (TQ) and X-326 pin F wire 0.5 (BK/YE) X-326 pin H wire 0.5 (TQ) and ground. If a short circuit or a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

Check the raise/work switch. A. With the switch in the work position, check between the connector: X-326 pin G and the connector X-326 pin F X-326 pin F and the connector X-326 pin H. If an open circuit is indicated, replace the raise/work switch. B. If the switch is okay, continue to step 6

Check for an open circuit. A. Disconnect the connectors X-210 and X-230 of the controller. Check between the connector: 47538922 29/05/2013

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X-326 pin G wire 0.5 (GN/BK) and X-210 pin 18 wire 0.5 (GN/BK) X-326 pin H wire 0.5 (TQ) and X-230 pin 6 wire 0.5 (TQ). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 7 7.

Check for a short circuit or a short to ground. A. Check between: X-326 pin F wire 0.5 (BK/YE) and X-326 pin G wire 0.5 (GN/BK) X-326 pin F wire 0.5 (BK/YE) and ground X-326 pin G wire 0.5 (GN/BK) and ground X-326 pin H wire 0.5 (TQ) and X-326 pin F wire 0.5 (BK/YE) X-326 pin H wire 0.5 (TQ) and ground. If a short circuit or a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect the connector X-326 of the lift/work switch. Check between the connector: X-326 pin F wire 0.5 (BK/YE) and F-009 (5A) wire 1.0 (BK/YE) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, continue to step 9

Check the raise/work switch. A. Check between: X-326 pin F and X-326 pin E X-326 pin F and X-326 pin H with the raise/work switch kept in the position for raising X-326 pin F and X-326 pin G X-326 pin F and X-326 pin H with the raise/work switch kept in the position for lowering. If an open circuit is indicated in either test, remove and replace the switch. B. If the switch is okay, continue to step 10

10. Check for a short circuit. A. Disconnect the connectors X-210 and X-230 of the controller. Check between the connector: X-210 pin 18 wire 0.5 (GN/BK) and X-210 pin 20 wire 0.5 (BR/WH) X-210 pin 18 wire 0.5 (GN/BK) and X-230 pin 6 wire 0.5 (TQ) X-210 pin 20 wire 0.5 (BR/WH) and X-230 pin 6 wire 0.5 (TQ). If a short circuit is indicated, repair the short between the connectors X-210 pin 18 (GN/BK) and pin 20 (BR/ WH) and X-230 pin 6 (TQ) of the controller and the connector X-326 of the raise/work switch or replace the wiring harness as required. B. If a short circuit is not indicated, continue to step 11 11. Check for an open circuit. A. Check between the connector: X-326 pin E wire 0.5 (BR/WH) and X-210 pin 20 wire 0.5 (BR/WH) X-326 pin G wire 0.5 (GN/BK) and X-210 pin 18 wire 0.5 (GN/BK) X-326 pin H wire 0.5 (TQ) and X-230 pin 6 wire 0.5 (TQ). If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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2005-Creeper engage fault NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty creeper solenoid 2. Faulty creeper rail switch 3. Faulty hydraulic circuit 4. Mechanical fault Solution: 1. Check for other error codes being displayed. A. If any other error codes are being displayed, continue to these tests. B. If no other error codes are displayed, continue to step 2 2. Clear the error code and test the system for normal operation. A. If the error code re-occurs, continue to step 3 3. Check the creeper solenoid. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, continue to step 4 4. Check the hydraulic pressures. A. If the pressures indicated are approximately 18 bar, possible mechanical fault within the transmission. B. If the pressure is low, continue to hydraulic troubleshooting procedures. C. If the pressures indicated are okay, continue to step 5 5. Check the creeper rail switch. A. Disconnect connector X-504. Remove the creeper rail switch. Check between the component side of the connector X-504 pin 1 and pin 2. Operate the switch, the readings should alternate between open and closed circuit. If the reading are not as expected, replace the creeper rail switch. B. If the readings are as expected, continue to step 6 6. Check for short to +Ve voltage. A. Check between X-504 pin 1 (WH/GN) and ground. If a voltage is indicated, repair or replace the harness as required. B. If a short to + Ve voltage is not indicated, the readings are as expected, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2013-Upshift and downshift switch ON error NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Tractor will continue to drive but attempts to shift will not be recognized. Possible failure modes: 1. Faulty connector 2. Both the upshift and downshift switches depressed at the same time 3. Faulty gear shift switch 4. Faulty upshift switch 5. Faulty downshift switch 6. Faulty harness 7. Faulty controller Solution: 1. Have both the upshift and downshift switches been depressed at the same time. A. Clear the error code and test the system for normal operation. B. If the error code re-occurs, continue to step 2 2. Check the upshift switch in H5. A. Turn the ignition key ON. Depress the upshift switch, d18 should be displayed as the switch is operated and extinguish when released. Repeat the test using the upshift switch located on the gear lever. If the display is okay, continue to step 3 B. If the display is not okay, continue to step 6 3. Check the harness connectors in H5. A. While still in H5 with the upshift switch released, wiggle the harness, the gear lever connector X-320, the upshift switch connector X-553 and the controller connector X-230 to check for a circuit fault. If d18 is displayed a fault is present, repair or replace as required. B. If d18 is not displayed, continue to step 4 4. Check the downshift switch in H5. A. Turn the ignition key ON. Depress the downshift switch, d17 should be displayed as the switch is operated and extinguish when released. Repeat the test using the downshift switch located on the gear lever. If the display is okay, continue to step 5 B. If the display is not okay, continue to step 6 5. Check the harness connectors in H5. A. While still in H5 with the downshift switch released, wiggle the harness, the gear lever connector X-320, the downshift switch connector X-554 and the controller connector X-230 to check for a circuit fault. If d17 is displayed a fault is present, repair or replace as required. B. If d17 is not displayed, download the correct level of software. If the fault re-occurs, remove and replace the controller. 6. Check for a short to a positive voltage. A. Turn the ignition key OFF. Disconnect the gear lever connector X-320, the upshift switch connector X-553, the downshift connector X-554 and the controller connector X-230. 47538922 29/05/2013

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Turn the ignition key ON. Check between connector: X-230 pin 11 (OR/TQ) and ground X-230 pin 10 (BL) and ground If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 7 7. Check for a short circuit. A. Turn the ignition key OFF. Check between connector X-230 pin 11 (OR/TQ) and X-230 pin 10 (BL). If a short circuit is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the gear shift switch.

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Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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Electrical systems - FAULT CODES

2027-Engine speed no signal NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: This fault code indicates an engine under speed has occurred. If engine speed falls below 500 RPM for 5 s, this fault code will occur. This fault code does not necessarily indicate an error status but is used more for information purposes and inhibit handling. Possible failure modes: 1. Information code indicating an engine under run has been detected Solution: 1. Check for the error code. A. Clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. If the error code does not display again or displays very infrequently, no action is necessary B. If the fault is still present, check to ensure that the driving conditions of the machine are not causing the error. If the driving conditions of the machine seem okay, download the correct level of software. If the fault reoccurs, remove and replace the engine controller.

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Electrical systems - FAULT CODES

3293-Fuel Metering Unit: maximum positive deviation of rail pressure exceeded Context: The Fuel Rail pressure control is executed with 2 devices, metering unit as feeding quantity control and pressure control valve (PCV) as pressure control. The Fuel rail pressure control can switch between the 3 states "only metering unit", "only PCV" and "both devices" depending on engine speed and requested fuel pressure. If the engine control unit (ECU) detects the rail pressure is lower than the desired pressure by less than the engine speed dependant threshold this error will occur. This error can be the result of a leak within the high pressure system (low efficiency of high pressure pump, internal leakage of injector, leaking pressure control valve) or too low pressure at the high pressure pump inlet (clogged filter, leaking low pressure tubes, electric pre-supply pump faulty, gear pump faulty).

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Electrical systems - FAULT CODES

3796-Diesel particulate filter pressure sensor 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

4564-EHR joystick - no communications NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty EHR joystick 4. Faulty central control unit ( CCU) software 5. Faulty controller Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the EHR joystick connector X-173, the inline connector X-100 and the controller connector X-200 A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for +12 Volts. A. Disconnect the connector X-173. Turn the ignition key switch ON. Measure the voltage between connector X-173 pin 1 (BK/YE) and ground. If the voltage indicated is less than approximately +12 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately +12 Volts, continue to step 4 4. Check for an open circuit. A. Turn the ignition key switch OFF. Check between connector X-173 pin 2 (BK) and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Disconnect connector X-200. Check between connectors: X-200 pin 21 (RD) and X-173 pin 3 (YE) X-200 pin 22 (BL) and X-173 pin 4 (BL) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 6 6. Check for other CAN error code(s). A. If other CAN error code(s) are indicated, repair the CAN error code(s) as required. B. If no other CAN error code(s) are indicated and the harness is okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present, remove and replace the EHR joystick. If the fault is still present, remove and replace the central control unit ( CCU) and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 11 (55.100.DP-C.20.E.11) Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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Electrical systems - FAULT CODES

CH-HOT OIL WARNING: displayed above 105 degress C Possible failure modes: 1. Transmission oil is hot - above 105°C Solution: 1.

A. If “CL” (10°C to 60°C) or “CH” (above 105°C) is displayed, after 4 seconds the display will return to oil temperature and the tractor may be operated to obtain the correct transmission oil temperature. If it is not practical to wait for the oil temperature to change, press either the up or down shift buttons while “CL” or “CH” is being displayed. The display will then show “Syn” and calibration can proceed.

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Electrical systems - FAULT CODES

CL-COLD OIL WARNING: displayed below 60 degrees C Possible failure modes: 1. Transmission oil is cold - between 10°C to 60°C Solution: 1.

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Electrical systems - FAULT CODES

U147-Synchroniser cannot be engaged Possible failure modes: 1. Faulty control solenoid 2. No oil pressure to the synchroniser 3. Faulty synchroniser Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U148-Range lever not in the high range position Possible failure modes: 1. Range lever is not in the high range position Solution: 1.

A. Select the high range position when required during the calibration.

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Electrical systems - FAULT CODES

U17-Seat switch not activated Possible failure modes: 1. Operator is not sitting in the seat 2. Open circuit between the seat switch and the instrument cluster 3. Seat switch faulty 4. 12 V supply to the switch is open circuit

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Electrical systems - FAULT CODES

U19-Oil temperature below 10Â°C, calibration not allowed Possible failure modes: 1. Transmission oil is very cold 2. Transmission oil temperature sensor open circuit 3. Oil temperature sensor faulty 4. Oil temperature sensor short to ground

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Electrical systems - FAULT CODES

U20-Handbrake is not set NOTE: Use the H5-ZD, d11 switch diagnostics of the instrument cluster to detect if the parking brake switch is connected. Possible failure modes: 1. The parking brake is not engaged 2. Open circuit between the parking brake switch and the instrument cluster 3. Parking brake switch faulty 4. 12 V supply to the switch is open circuit

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Electrical systems - FAULT CODES

U21-ERPM is below 1050, increase throttle NOTE: Use the HE menu ch 3 to see if the engine speed is being detected. Possible failure modes: 1. Operator has not set the correct engine speed 2. Open circuit between the engine speed sensor and the engine controller 3. CAN circuit faulty

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Electrical systems - FAULT CODES

U22-ERPM is above 1350, reduce throttle Possible failure modes: 1. Operator has not set the correct engine speed

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Electrical systems - FAULT CODES

U23-Shuttle lever is in neutral, shift lever to forward NOTE: Use the H5 switch diagnostics of the RI transmission control unit to detect if the switch is connected. Possible failure modes: 1. Operator has not selected forward on the shuttle lever 2. Open circuit between the shuttle lever and the central control unit ( CCU) 3. 12 V Supply to the shuttle lever is open circuit

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Electrical systems - FAULT CODES

U26-Clutch pedal is not up, release clutch pedal NOTE: Use the H9-ch48 in the transmission control unit to see if the clutch input is OK. Possible failure modes: 1. Operator has not released the clutch pedal 2. The clutch pedal potentiometer linkage is sticking or faulty

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Electrical systems - FAULT CODES

U27-C3 calibration value is too low Possible failure modes: 1. RPM dropped too soon 2. Clutch pressure is not being controlled properly 3. Engine speed adjusted whilst completing calibration Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U29-C4 calibration value is too low Possible failure modes: 1. RPM dropped too soon 2. Clutch pressure is not being controlled properly 3. Engine speed adjusted whilst completing calibration Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U31-Wheel speed sensed NOTE: If the brakes are okay, move the vehicle slightly forward and repeat the calibration. Possible failure modes: 1. The parking brake is not engaged 2. Brakes not working

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Electrical systems - FAULT CODES

U32-C1 calibration value is too low Possible failure modes: 1. RPM dropped too soon 2. Clutch pressure is not being controlled properly 3. Engine speed adjusted whilst completing calibration Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U34-C2 calibration value is too low Possible failure modes: 1. RPM dropped too soon 2. Clutch pressure is not being controlled properly 3. Engine speed adjusted whilst completing calibration Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U36-Max allowed clutch calibration value exceeded Possible failure modes: 1. The speed does not drop 2. No or low oil pressure to the clutch 3. Mechanical failure breaking the torque path

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Electrical systems - FAULT CODES

U37-Synchroniser potentiometer signal is out of range for the reverse position NOTE: Use the voltmeter to check the synchroniser potentiometer signal. If OK then repeat calibration to free up synchroniser. Possible failure modes: 1. Synchroniser potentiometer has been painted through production 2. Synchroniser potentiometer connector has been damaged 3. Synchroniser assembly is very tight / sticky Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U38-Synchroniser potentiometer signal is out of range for the forward position NOTE: Use the voltmeter to check the synchroniser potentiometer signal. If OK then repeat calibration to free up synchroniser. Possible failure modes: 1. Synchroniser potentiometer has been painted through production 2. Synchroniser potentiometer connector has been damaged 3. Synchroniser assembly is very tight / sticky Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U39-Synchroniser did not move toward reverse, even at maximum pressure NOTE: Remove the transmission top cover and watch the synchroniser movement to help detect failure or use H9 and look at the potentiometer signal with a voltmeter. Possible failure modes: 1. The forward and reverse solenoid connectors need to be swapped 2. The reverse solenoid is faulty 3. No oil pressure to shift the synchroniser 4. Synchroniser potentiometer has been painted through production 5. Synchroniser potentiometer connector has been damaged Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U40-Synchroniser did not move toward forward, even at maximum pressure NOTE: Remove the transmission top cover and watch the synchroniser movement to help detect failure or use H9 and look at the potentiometer signal with a voltmeter. Possible failure modes: 1. The forward and reverse solenoid connectors need to be swapped 2. The forward solenoid is faulty 3. No oil pressure to shift the synchroniser 4. Synchroniser potentiometer has been painted through production 5. Synchroniser potentiometer connector has been damaged Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U41-Synchroniser pot signal is out of range for the 4 position NOTE: Use the voltmeter to check the synchroniser potentiometer signal. If OK then repeat calibration to free up syncro. Cause: Possible failure modes: 1. Synchroniser potentiometer has been painted through production 2. Synchroniser potentiometer connector has been damaged 3. Synchroniser assembly is very tight / sticky Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U42-Synchroniser pot signal is out of range for the 5 position NOTE: Use the voltmeter to check the synchroniser potentiometer signal. If OK then repeat calibration to free up synchroniser. Possible failure modes: 1. Synchroniser potentiometer has been painted through production 2. Synchroniser potentiometer connector has been damaged 3. Synchroniser assembly is very tight / sticky Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U43-Synchroniser did not move toward 4, even at max pressure NOTE: Remove the transmission top cover and watch the synchroniser movement to help detect failure or use H9 and look at the potentiometer signal with a voltmeter. Possible failure modes: 1. The 1-4 and 5-8 solenoid connectors need to be swapped 2. The 1-4 solenoid is faulty 3. No oil pressure to shift the synchroniser 4. Synchroniser potentiometer has been painted through production 5. Synchroniser potentiometer connector has been damaged Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U44-Synchroniser did not move toward 5, even at max pressure NOTE: Remove the transmission top cover and watch the synchroniser movement to help detect failure or use H9 and look at the potentiometer signal with a voltmeter. Possible failure modes: 1. The 1-4 and 5-8 solenoid connectors need to be swapped 2. The 5-8 solenoid is faulty 3. No oil pressure to shift the synchroniser 4. Synchroniser potentiometer has been painted through production 5. Synchroniser potentiometer connector has been damaged Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

U82-No 12VD: no power for C3 and C4 solenoids Possible failure modes: 1. Clutch pedal not released 2. Wiring fault to X-200 pin 8 (YE/BK) 3. Faulty central control unit CCU Solution: 1.

A. Repair the fault and restart the calibration procedure.

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Electrical systems - FAULT CODES

14015-5V reference voltage - too high Control Module : ADIC NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: A voltage greater than 6 V is detected at the analog-digital instrument cluster ( ADIC) connector X-460 pin 1, wire 0.5 (TQ) and/or pin 14, wire 0.5 (TQ) (5V ref) or an internal short circuit within the instrument cluster ( ADIC) is present. Possible failure modes: 1. Faulty connectors 2. Faulty electrical component on reference line 3. Wiring fault 4. Faulty analog-digital instrument cluster ( ADIC) Solution: 1. Check for other cluster related codes being displayed. A. If any other cluster related error codes are being displayed, continue to these tests. B. If no other cluster related error code is displayed, continue to step 2 2. Check the 5 V sensor supply using H9, channel 5 and then channel 6. A. If the values displayed are between 4500 - 5500 mV , while still in H9 Channel 5 and then channel 6, wiggle the harness to check for an intermittent circuit. Channel 5 and/or channel 6 values will change if an intermittent circuit is indicated, repair or replace as required. B. If the values displayed are not between 4500 - 5500 mV, continue to step 3 3. Check for a short to positive. A. Disconnect the connector X-460. Turn the ignition key switch ON. Check between connector: X-460 pin 1 (TQ) and ground X-460 pin 14 (TQ) and ground If a voltage is indicated, continue to step 4 B. If the harness is okay, download the correct level of software. If the fault occurs again, remove and replace the analog-digital instrument cluster ( ADIC). 4. Check the 5 V sensor supply using H9, channel 5 and then channel 6. A. Turn the ignition switch OFF. Connect the connector X-460. Turn the ignition key switch ON. While checking the value displayed in the cluster, disconnect the cluster components which are connected to connector X-460 pin 1, wire 0.5 (TQ) and pin 14, wire 0.5 (TQ) (5V ref) one at a time. If the value in the cluster changes to the correct value between 4500 - 5500 mV when any of these components is disconnected, remove and replace the component. B. If the value in the cluster is still incorrect, a short to power is present in the harness, repair or replace the harness as required.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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Electrical systems - FAULT CODES

14016-5V reference voltage - too low Control Module : ADIC NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: A voltage less than 4 V is detected at the analog-digital instrument cluster ( ADIC) connector X-460 pin 1, wire 0.5 (TQ) and/or pin 14, wire 0.5 (TQ) (5V ref) or an internal short circuit within the instrument cluster ( ADIC) is present. Possible failure modes: 1. Faulty connectors 2. Faulty electrical component on reference line 3. Wiring fault 4. Faulty analog-digital instrument cluster ( ADIC) Solution: 1. Check for other cluster related codes being displayed. A. If any other cluster related error codes are being displayed, continue to these tests. B. If no other cluster related error code is displayed, continue to step 2 2. Check the 5 V sensor supply using H9, channel 5 and then channel 6. A. If the values displayed are between 4500 - 5500 mV , while still in H9 Channel 5 and then channel 6, wiggle the harness to check for an intermittent circuit. Channel 5 and/or channel 6 values will change if an intermittent circuit is indicated, repair or replace as required. B. If the values displayed are not between 4500 - 5500 mV, continue to step 3 3. Check for a short to ground. A. Disconnect the controller connector X-460 and check between connector: X-460 pin 1 (TQ) and ground X-460 pin 14 (TQ) and ground If a short to ground is indicated, continue to step 4 B. If the harness is okay, download the correct level of software. If the fault occurs again, remove and replace the analog-digital instrument cluster ( ADIC). 4. Check the 5 V sensor supply using H9, channel 5 and then channel 6. A. Connect the connector X-460. Turn the ignition switch ON. While checking the value displayed in the cluster, disconnect the cluster components which are connected to connector X-460 pin 1, wire 0.5 (TQ) and pin 14, wire 0.5 (TQ) (5V ref) one at a time. If the value in the cluster changes to the correct value between 4500 5500 mV when any of these components is disconnected, remove and replace the component. B. If the value in the cluster is still incorrect, a short to ground is present in the harness, repair or replace the harness as required.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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Electrical systems - FAULT CODES

14021-Cranking line - shorted to +12V Control Module : ADIC NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: A short to 12 V has been detected at the analog-digital instrument cluster ( ADIC) connector X-460 pin 17, wire 0.5 (BL/YE) for more than 1 minute. Possible failure modes: 1. Faulty connectors 2. Wiring fault 3. Ignition relay faulty 4. Faulty analog-digital instrument cluster ( ADIC) Solution: 1. Check for other error codes being displayed. A. If any other error code is being displayed, continue to these tests. B. If no other error code is displayed, continue to step 2 2. Check the instrument cluster ( ADIC) connector X-460 and the ignition relay K100 connector X-533 A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for a short to positive. A. Place the shuttle lever in Neutral. Remove the instrument cluster and leave it connected. Start the unit. Using a suitable back probe pin check between the back of connector X-460 pin 17, wire 0.5 (BL/YE) and ground. If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, download the correct level software. If the fault occurs again, remove and replace the analog-digital instrument cluster ( ADIC).

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Electrical systems - FAULT CODES

Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

01 01 15 17

(55.100.DP-C.20.E.01) (55.100.DP-C.20.E.01) (55.100.DP-C.20.E.15) (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

14022-Cranking line - shorted to GND Control Module : ADIC NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: A short to ground has been detected at the analog-digital instrument cluster ( ADIC) connector X-460 pin 17, wire 0.5 (BL/YE) or a jump start has occurred. Possible failure modes: 1. Engine has been jump started 2. Faulty connectors 3. Wiring fault 4. Ignition relay faulty 5. Faulty analog-digital instrument cluster ( ADIC) Solution: 1. Check for other error codes being displayed. A. If any other error code is being displayed, continue to these tests. B. If no other error code is displayed, continue to step 2 2. Check the instrument cluster ( ADIC) connector X-460 and the ignition relay K100 connector X-533. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for a short to ground. A. Place the shuttle lever in Neutral. Disconnect connectors X-460 and X-533. Check between connector X-460 pin 17, wire 0.5 (BL/YE) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the analog-digital instrument cluster ( ADIC).

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Electrical systems - FAULT CODES

Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

01 01 15 17

(55.100.DP-C.20.E.01) (55.100.DP-C.20.E.01) (55.100.DP-C.20.E.15) (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

14051-Fuel level sensor - short circuit to supply voltage or open circuit Control Module : ADIC Possible failure modes: 1. Faulty connectors 2. Fuel tank level sensor faulty 3. Wiring fault 4. Faulty analog-digital instrument cluster ( ADIC) Solution: 1. Check the fuel tank level sensor potentiometer in H9, channel 25. A. Remove the fuel level sensor. With the connector still connected move sender from the maximum to minimum position. If the values displayed do not change continuously between 850 mV and 3670 mV, continue to step 2 B. If the values displayed are okay, while in H9 channel 25 wiggle the harness and connectors to check for a intermittent circuit. Channel 25 values will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the fuel level sensor connector X-354, instrument cluster ( ADIC) connector X-450 and the transmission cab main connector X-300. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3 3. Check the fuel level sensor operation. A. Disconnect the connector X-354. Check the connector: X-354 between pins 1 and 2 If the resistances indicated are not between 250 ÎŠ at full and 28 ÎŠ at empty, remove and replace the sender. B. If the resistances indicated are okay, continue to step 4 4. Check for an open circuit. A. Disconnect the connector of the instrument cluster ( ADIC) X-450. Check between: X-354 pin 2, wire 1.0 (BR) and X-450 pin 2 wire 0.5 (BR). X-354 pin 1, wire 1.0 (BK) and X-450 pin 6 , wire 0.5 (BK). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue with step 5 5. Check for a short to positive. A. Turn the ignition key switch ON. Check between the connector: X-354 pin 2, wire 1.0 (BR) and ground If a short to positive is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the analog-digital instrument cluster ( ADIC).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

14052-Fuel level sensor - short circuit to ground Control Module : ADIC Possible failure modes: 1. Faulty connectors 2. Fuel tank level sensor faulty 3. Wiring fault 4. Faulty analog-digital instrument cluster ( ADIC) Solution: 1. Check the fuel level sensor potentiometer in H9, channel 25. A. Remove the fuel level sensor. With the connector still connected move sensor from the maximum to minimum position. If the values displayed do not change continuously between 850 mV and 3670 mV, continue to step 2 B. If the values displayed are okay, while in H9 channel 25 wiggle the harness and connectors to check for a intermittent circuit. Channel 25 values will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the fuel level sensor connector X-354, instrument cluster ( ADIC) connector X-450 and the transmission cab main connector X-300. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3 3. Check the fuel level sensor operation. A. Disconnect the connector X-354. Check the connector: X-354 between pins 1 and 2 If the resistances indicated are not between 250 ÎŠ at full and 28 ÎŠ at empty, remove and replace the sensor. B. If the resistances indicated are okay, continue to step 4 4. Check for a short to ground. A. Disconnect the connectors X-450. Check between the connector: X-354 pin 2, wire 1.0 (BR) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the analog-digital instrument cluster ( ADIC).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

14058-Seat switch closed over 25 hours Control Module : ADIC Context: The analog-digital instrument cluster ( ADIC) sees no change on the operator present switch in the last 25 h of continuous work, switch jammed on or shorted to ground. Possible failure modes: 1. Faulty connector 2. Operator present switch faulty 3. Wiring fault 4. Faulty analog-digital instrument cluster ( ADIC) Solution: 1. Check the operator present seat switch X-355, in H9 channel 26. A. With the driver seated the display must show a value of approximately 1430 mV, with the driver standing, the display will show a value of approximately 2870 mV. If the values displayed are not okay, continue to step 2 B. If the values displayed are okay, while still in H9 channel 26, wiggle the harness and the connector of the instrument cluster ( ADIC) X-450 and of the operator present seat switch X-355 to check for an intermittent circuit. Channel 26 values will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check connectors X-355 of the operator present seat switch and X-450 of the instrument cluster ( ADIC) . A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3. 3. Check the operator present seat switch. A. Disconnect the connector X-355. Check the resistance between: X-355 pin 1 and pin 2 With the driver seated the resistance must be approximately 500 ÎŠ, with the driver standing it must be approximately 2000 ÎŠ. If the resistances indicated are not okay, replace the operator present seat switch. B. If the switch is okay, continue to step 4 4. Check for a short to ground. A. Disconnect the connector X-450. Check between connector X-355 pin 2, wire 0.5 (GN) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the analog-digital instrument cluster ( ADIC).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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14061-Air brake pressure short to Vcc or option set but sensor not connected Control Module : ADIC NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: Air brake pressure detection below 5.2 bar (75.4 psi). If at key on the analog-digital instrument cluster ADIC detects the presence of the Air Brake sensor (P>0) whilst the set mode indicates NO AIR BRAKE (see HH menu description, H3 setting), an error code should be generated. When the Pressure is: (P > 9 bar (130.5 psi)), it shall mean that we could have a failed sensor or a problem on the system or a problem on the wire harness. Possible failure modes: 1. Faulty connectors 2. Faulty air brake pressure sensor 3. Faulty harness 4. Analog-digital instrument cluster faulty Solution: 1. Check the machine is equipped with air brakes. A. If the unit is not equipped with air brakes, using H3 menu and selecting ( ZD ) module, make sure the air brake option on the analog-digital instrument cluster is disabled. B. If the unit is equipped with air brakes, using H3 menu and selecting ( ZD ) module, make sure the air brake option is enabled, continue to step 2 2. Check the air brake pressure sensor in H9 menu channel 24. A. Under normal operating conditions, check the air brake pressure value indicates approximately between 376 4536 mV . If the value indicated is not approximately between 376 - 4536 mV, continue to step 3 B. If values displayed are okay, while in H9 channel 24 wiggle the harness and connectors to check for a intermittent circuit. Channel 24 values will change if an intermittent circuit is detected, repair or replace as required. 3. Check the air brake pressure connector X-178 , the instrument cluster connectors X-377, X-450, X-460 and the inline harness connectors X-300 and X-372 . A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 4 4. Check for a short to ground. A. Disconnect the air brake pressure connector X-178, the connectors of the control unit X-377, X-450 and X-460. Check between connector: X-178 pin 1, wire 0.5 (BK/YE) and ground X-178 pin 2, wire 1.0 (WH) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for a short to positive voltage. A. Turn the ignition key switch ON. Check between connector: X-178 pin 1, wire 0.5 (BK/YE) and ground X-178 pin 2, wire 1.0 (WH) and ground 47538922 29/05/2013

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X-178 pin 3, wire 0.5 (BK) and ground If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 6 6. Check for an open circuit. A. Turn the ignition key switch OFF. Check between connectors: X-178 pin 1, wire 0.5 (BK/YE) and X-377 pin 5, wire 0.5 (BK/YE) X-178 pin 2, wire 1.0 (WH) and X-460 pin 12, wire 1.0 (WH) X-178 pin 3, wire 0.5 (BK) and X-450 pin 6, wire 0.5 (BK) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the air brake pressure sensor. If the fault is still present, download the correct level of software. If the fault re-occurs, remove and replace the instrument cluster.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16) Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

14093-Seat switch signal short to + 12V or open circuit Control Module : ADIC Possible failure modes: 1. Faulty connectors 2. Operator present seat switch faulty 3. Wiring fault 4. Faulty analog-digital instrument cluster ( ADIC) Solution: 1. Check the operator present seat switch X-355, in H9 channel 26. A. With the driver seated the display must show a value of approximately 1430 mV, with the driver standing, the display will show a value of approximately 2870 mV. If the values displayed are not okay, continue to step 2 B. If the values displayed are okay, while still in H9 channel 26, wiggle the harness and the connector of the instrument cluster ( ADIC) X-450 and of the operator present seat switch X-355 to check for an intermittent circuit. Channel 26 values will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the operator present seat switch. A. Disconnect the connector X-355. Check the resistance between: X-355 pin 1 and pin 2 With the driver seated the resistance must be approximately 500 Ω, with the driver standing it must be approximately 2000 Ω. If the resistances indicated are not okay, replace the operator present seat switch. B. If the switch is okay, continue to step 3 3. Check for an open circuit. A. Disconnect the connector X-450. Check between: X-355 pin 1, wire 0.5 (BK) and X-450 pin 6 wire 0.5 (BK). X-355 pin 2, wire 0.5 (GN) and X-450 pin 1, wire 0.5 (GN) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 4 4. Check for a short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-355 pin 2, wire 0.5 (GN) and ground If a short to positive is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the analog-digital instrument cluster ( ADIC).

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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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14094-Seat switch - short circuit to ground Control Module : ADIC Possible failure modes: 1. Faulty connectors 2. Operator present seat switch faulty 3. Wiring fault 4. Faulty analog-digital instrument cluster ( ADIC) Solution: 1. Check the operator present seat switch X-355, in H9 channel 26. A. With the driver seated the display must show a value of approximately 1430 mV, with the driver standing, the display will show a value of approximately 2870 mV. If the values displayed are not okay, continue to step 2 B. If the values displayed are okay, while still in H9 channel 26, wiggle the harness and the connector of the instrument cluster ( ADIC) X-450 and of the operator present seat switch X-355 to check for an intermittent circuit. Channel 26 values will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the operator present seat switch. A. Disconnect the connector X-355. Check the resistance between: X-355 pin 1 and pin 2 With the driver seated the resistance must be approximately 500 ÎŠ, with the driver standing it must be approximately 2000 ÎŠ. If the resistances indicated are not okay, replace the operator present seat switch. B. If the switch is okay, continue to step 3 3. Check for a short to ground. A. Disconnect the connector X-450. Check between: X-355 pin 2 , wire 0.5 (GN) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the analog-digital instrument cluster ( ADIC).

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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

14100-Air brake option not configured Control Module : ADIC Cause: The air brake option has not been configured, the analog-digital instrument cluster ( ADIC) detects the pressure switch via the wire. Solution: 1. Check that the air brake option has been configured. A. Enter the HH MENU programs of the ADIC ( ZD ), in H3 configure the air brake. NOTE: To enter the HH MENU programs, refer to dedicated chapter in this manual.

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Electrical systems - FAULT CODES

14200-Battery isolator switch closed to battery at Key ON for more than 30 seconds Control Module : ADIC NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation Possible failure modes: 1. Faulty connector 2. Battery isolator switch faulty 3. Wiring fault 4. Faulty analog-digital instrument cluster ( ADIC) Solution: 1. Check the battery isolator switch connector X-197 and the connector of the analog-digital instrument cluster ( ADIC) X-460. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the battery isolator switch in H5. A. The display will show d_ _. Move the battery isolator switch between the set and reset positions several times, and check the display changes to d61. If the display does not change, continue to step 3 B. If the values displayed are okay, while still in H5 and holding the switch in the reset or set position, wiggle the harness, the battery isolator connector X-197, and the connector of the analog-digital instrument cluster ( ADIC) to check for an intermittent circuit. The H5 display will change if an intermittent circuit is detected. Repair or replace as necessary. C. If the harness is okay, download the correct level software. If the fault occurs again, remove and replace the analog-digital instrument cluster ( ADIC). 3. Check the battery isolator switch. A. Disconnect the connector X-197. Check the continuity between: X-197 pin 1 and pin 2. With the battery isolator switch in the neutral position it should indicate a closed circuit. With the battery isolator switch in the reset position it should indicate an open circuit. Always open circuit between X-197 pin 1 and pin 3 Open circuit in neutral position between X-197 pin 2 and pin 3 Closed circuit in reset position between X-197 pin 2 and pin 3 If the continuity indicated is not okay remove and replace the battery isolator switch. B. If the battery isolator switch is okay, continue to step 4 4. Check for an open circuit. A. Turn ignition key switch â&#x20AC;&#x2DC;OFFâ&#x20AC;&#x2122;. Disconnect the connector of the analog-digital instrument cluster ( ADIC) X-460. Check between the connector: X-197 pin 3, wire 0.5 (GY/BL) and X-460 pin 2, wire 0.5 (GY/BL) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to 5 5. Check for a short to power A. Turn the ignition key switch ON and check between: 47538922 29/05/2013

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X-197 pin 3, wire 0.5 (GY/BL) and ground If a positive voltage is indicated, repair or replace the harness as required B. If the harness is okay, continue to step 6 6. Check for a short circuit. A. Check between the connectors X-197 pin 1, wire 0.5 (YE) and X-197 pin 3, wire 0.5 (GY/BL) If a short circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault reoccurs, remove and replace the analog-digital instrument cluster ( ADIC).

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For ISO markets Wire harnesses For NA markets Wire harnesses Wire harnesses Wire harnesses -

Electrical schematic frame 01 (55.100.DP-C.20.E.01) Electrical schematic frame 01 (55.100.DP-C.20.E.01) Electrical schematic frame 02 (55.100.DP-C.20.E.02) Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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14900-CCU module missing Control Module : ADIC NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation Possible failure modes: 1. Faulty connectors 2. Wiring fault 3. Central control unit ( CCU) fault Solution: 1. Check the connector of the analog-digital instrument cluster ( ADIC) X-450 and the connectors of the central control unit ( CCU) X-200, X-220 and X-240. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check for + 12 V. A. Disconnect the connectors X-200, X-220 and X-240. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between connector: X-200 pin 1, wire 0.75 (OR/BK) and ground X-200 pin 2, wire 0.75 (OR/BK) and ground X-200 pin 3, wire 0.75 (OR/BK) and ground X-200 pin 14, wire 0.5 (BL/WH) and ground X-200 pin 20, wire 1.0 (BK/YE) and ground X-240 pin 34, wire 1.0 (GY/BL) and ground If the indicated voltage is not + 12 V, repair or replace the harness as required. B. If + 12 V is indicated, continue to step 3 3. Check for an open circuit. A. Turn ignition key switch to OFF position. Check for an open circuit between connector: X-200 pin 19, wire 1.0 (BK) and ground X-200 pin 25, wire 1.0 (BK) and ground X-200 pin 26, wire 1.0 (BK) and ground X-220 pin 21, wire 1.0 (BK) and ground X-220 pin 26, wire 1.0 (BK) and ground If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 4 4. Check for an open circuit on the CAN BUS. A. Disconnect the connector of the analog-digital instrument cluster ( ADIC) X-450. Check between: X-200 ( CAN_H) pin 15, wire 0.75 (YE) and X-450 ( CAN_H) pin 3, wire 0.75 (YE) X-200 ( CAN_L) pin 16, wire 0.75 (GN) and X-450 ( CAN_L) pin 4, wire 0.75 (GN) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire Wire Wire Wire Wire

harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03) harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04) harnesses - Electrical schematic frame 11 (55.100.DP-C.20.E.11) harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15) harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

14901-Engine controller missing Control Module : ADIC NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation Possible failure modes: 1. Faulty connectors 2. Wiring fault 3. Engine control unit ( ECU) fault Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the tractor under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other error codes displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check the connector of the instrument cluster ( ADIC) X-450 and the connector of the engine control unit ( ECU) X-937. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 4 4. Check all power supplies and grounds to the engine control unit ( ECU) . A. If a fault is indicated, repair or replace the harness as required. B. If no faults are indicated, continue to step 5 5. Check for an open circuit on the CAN BUS. A. Disconnect the connector ( ADIC) X-450 and the connector ( ECU) X-937. Check between: X-937 ( CAN_H) pin 24, wire 0.75 (YE) and X-450 ( CAN_H) pin 3, wire 0.75 (YE) X-937 ( CAN_L) pin 25, wire 0.75 (GN) and X-450 ( CAN_L) pin 4, wire 0.75 (GN) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the engine control unit ( ECU).

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Wire Wire Wire Wire Wire

harnesses - Electrical schematic frame 01 (55.100.DP-C.20.E.01) harnesses - Electrical schematic frame 01 (55.100.DP-C.20.E.01) harnesses - Electrical schematic frame 11 (55.100.DP-C.20.E.11) harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17) harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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14908-TECU module missing Control Module : ADIC NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation Possible failure modes: 1. Faulty connectors 2. Wiring fault 3. Tractor electronic control unit ( TECU) fault Solution: 1. Check the connector of the instrument cluster ( ADIC) X-450, the connectors of the tractor electronic control unit ( TECU) X-204 and the inline connector X-180. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check for + 12 V. A. Disconnect the connectors X-204 . Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between connector: X-204 pin 10, wire 0.75 (RD/GN) and ground X-204 pin 16, wire 0.75 (RD/BK) and ground If the indicated voltage is not + 12 V, repair or replace the harness as required. B. If + 12 V is indicated, continue to step 3 3. Check for an open circuit. A. Turn ignition switch to OFF position. Check for an open circuit between connector: X-204 pin 11, wire 0.75 (BK) and ground X-204 pin 21, wire 0.75 (BK) and ground If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 4 4. Check for an open circuit on the CAN BUS. A. Disconnect the connector ( ADIC) X-450. Check between: X-204 ( CAN_H) pin 4, wire 0.75 (YE) and X-450 ( CAN_H) pin 3, wire 0.75 (YE) X-204 ( CAN_L) pin 5, wire 0.75 (GN) and X-450 ( CAN_L) pin 4, wire 0.75 (GN) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the tractor electronic control unit ( TECU).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 12 (55.100.DP-C.20.E.12) Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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1002-Radar sensor - disconnected or speed too low Control Module : CCU Possible failure modes: 1. Faulty connectors 2. Fuse F-009 ( 5 A) faulty 3. Radar faulty 4. Wiring fault 5. Central control unit ( CCU) fault Solution: 1. Check the connector of the radar X-333, the cab-transmission connector X-188 and the connector of the control unit ( CCU) X-210. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the radar power supply. A. Disconnect the connector of the radar X-333, turn the ignition key switch ON, check whether + 12 V is indicated on the connector X-333 pin 3 wire 1.0 (BK/YE). If + 12 V is indicated, continue to 3 B. If + 12 V is not indicated, check fuse F-009. If the fuse is okay, repair or replace the harness as required. 3. Check for an open circuit. A. Disconnect the connector of the central control unit ( CCU) X-210. Check between the connectors: X-210 pin 19 wire 1.0 (BR/YE) and X-333 pin 4 wire 1.0 (BR/YE) X-210 pin 33 wire 1.0 (BK/WH) and X-333 pin 1wire 1.0 (BK/WH) If an open circuit is indicated, repair or replace the harness as required. B. Check between the connector X-333 pin 2 wire 1.0 (BK) and ground. If an open circuit is indicated, repair or replace the harness as required. C. Turn the ignition key switch OFF, check whether + 12 V is indicated on the connector X-333 pin 4 wire 1.0 (BR/YE).If an open circuit is indicated, repair or replace the harness as required. If an open circuit is not indicated, continue to 4 4. Check for a short to ground. A. Check between the connector: X-333 pin 1 wire 1.0 (BK/WH) and ground X-333 pin 3 wire 1.0 (BK/YE) and ground X-333 pin 4 wire 1.0 (BR/YE) and ground If a short to ground is indicated, repair or replace the harness as required. If a short to ground is not indicated, continue to 5 5. Check the position of the radar. A. If the radar is pointing at the tractor wheel or excessively vibrating, point the radar at the ground and tighten the fixings. B. If the radar mounting and position is okay, remove and replace the radar assembly. C. If the error is still present, download the correct level of software. If the error is repeated, remove and replace the central control unit ( CCU).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

1003-Radar sensor and transmission output speed sensor - speed difference too high Control Module : CCU Cause: No signal from speed sensor. Possible failure modes: 1. Faulty connector 2. Incorrect tractor performance monitor radar alignment 3. Faulty speed sensor 4. Faulty tractor performance radar 5. Faulty Wiring 6. Faulty speed pickup gear Solution: 1. Check for error codes being displayed. A. If other error codes are displayed, continue to these tests. B. If the connectors are okay, continue to step 2 2. Check the position of the radar. A. If the radar is pointing at the tractor wheel or excessively vibrating, point the radar at the ground and tighten the fixings. B. If the speed sensor is okay, continue to step 3 3. Check the speed sensor. A. If the speed sensor is loose in the parking brake housing or damaged, re-tighten or remove and replace the speed sensor as required. B. If the radar mounting and position is okay,continue to step 4 4. Check the speed pickup gear. A. Remove the speed sensor and check for damage to the speed pickup gear inside the parking brake housing. If any damage is indicated, disassemble the housing and replace the speed pickup gear. B. If the speed pickup gear is okay,

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Electrical systems - FAULT CODES

1004-Transmission output speed sensor - signal too high Control Module : CCU Possible failure modes: 1. Faulty connector 2. Faulty speed sensor 3. Faulty harness 4. Faulty speed pickup gear Solution: 1. Check for other error codes being displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed,continue to step 2 2. Check the speed sensor X-309. A. If the speed sensor is loose in the rear axle housing or damaged, re-tighten or remove and replace the speed sensor as required. B. If the wheel speed sensor is okay, continue to step 3 3. Check the speed pickup gear. A. Remove the speed sensor and check for damage to the speed pickup gear inside the rear axle. If any damage is indicated, disassemble the rear axle and replace the speed pickup gear. B. If the speed pickup gear is okay, remove and replace the speed sensor.

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Electrical systems - FAULT CODES

1006-Hitch slip control potentiometer - signal too low Control Module : CCU Cause: SLIP CONTROL POTENTIOMETER SIGNAL TOO LOW (SHORT OR OPEN CIRCUIT) Possible failure modes: 1. Faulty connector 2. Faulty slip control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the slip control potentiometer in H9, CH. 37. A. Turn the slip control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 570 - 4430 mV, continue to step 2 B. If the values displayed are okay, while still in H9, CH. 37 wiggle the harness and the EDC control panel connector X-327, the connectors X-200 and X-210 of the controller to check for an intermittent circuit. The values of CH 37 will change if an intermittent circuit is indicated;Repair or replace as necessary. 2. Check the slip control potentiometer. A. Remove the EDC control panel and disconnect the connector X-327. While turning the slip control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: X-327 pin 5 and X-327 pin 7 X-327 pin 6 and X-327 pin 7. If the resistances indicated are not between 80 - 340 ÎŠ, replace the control panel. B. If the EDC control panel is okay, continue to step 3 3. Check for a short to ground. A. Check between (wire side): X-327 pin 7 wire 0.5 (BL/YE) and ground X-327 pin 5 wire 0.5 (TQ/WH) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 4 4. Check for an open circuit. A. Disconnect the connectors X-200 and X-210 of the controller. Check between: X-200 pin 23 wire 1.0 (BK/WH) and X-327 pin 6 wire 0.5 (BK/WH) X-210 pin 7 wire 0.5 (BL/YE) and X-327 pin 7 wire 0.5 (BL/YE) X-210 pin 17 wire 1.0 (TQ/WH) and X-327 pin 5 wire 0.5 (TQ/WH). If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14) Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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Electrical systems - FAULT CODES

1007-Hitch slip control potentiometer - signal too high Control Module : CCU Cause: SLIP CONTROL POTENTIOMETER SIGNAL TOO HIGH (SHORT TO + 12 V) Possible failure modes: 1. Faulty connector 2. Faulty slip control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the slip control potentiometer in H9, CH. 37. A. Turn the slip control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 570 - 4430 mV, continue to step 2 B. If the values displayed are okay, while still in H9, CH. 37 wiggle the harness and the EDC control panel connector X-327, the connectors X-200 and X-210 of the controller wiring to check for an intermittent circuit. The values of CH 37 will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the slip control potentiometer. A. Remove the EDC control panel and disconnect the connector X-327. While turning the slip control knob fully clockwise and then fully counter clockwise, measure the resistance between the component side of connector: X-327 pin 5 and X-327 pin 7 X-327 pin 6 and X-327 pin 7. If the resistances indicated are not between 80 - 340 ÎŠ, replace the control panel. B. If the EDC control panel is okay, continue to step 3 3. Check for a short to + 8 V or + 12 V. A. Turn the ignition key switch ON. Measure the voltage, with the panel disconnected, between the connector: X-327 pin 5 wire 0.5 (TQ/WH) and ground. If the voltage indicated is greater than + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 4 4. Check for a short circuit to a positive voltage. A. Measure the voltage between the connector: X-327 pin 7 Wire 0.5 (BL/YE) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1009-Hitch position control switches - implausible signals or signal at key on Control Module : CCU Possible failure modes: 1. Faulty connector 2. HPL fender switch(es) sticking 3. Faulty HPL fender switch 4. Wiring harness faulty 5. Faulty controller Solution: 1. Check the HPL fender switches are not sticking in the raise or lower position. A. If the switches are sticking, clean, repair or replace as required. B. If the fender switches are not sticking, continue to step 2 2. Check the HPL fender switches have not been operated simultaneously. A. Clear the error codes. Test the system for normal operation. If error code 1009 is still displayed, continue to step 3 3. Check the connector X-329 of the HPL switch mounted on the LH fender, the connector X-330 of the HPL switch mounted on the RH fender and the connector X-210 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 4 4. Check for a short circuit to positive voltage. A. Disconnect the connectors X-329 and X-330. Turn the ignition key switch ON. Measure the voltage between connector: X-330 pin 3 wire 0.5 (RD/WH) and ground X-330 pin 1 wire 0.5 (RD/BL) and ground X-329 pin 3 wire 0.5 (RD/WH) and ground X-329 pin 1 wire 0.5 (RD/BL) and ground. If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated continue to step 5 5. Check the L/H HPL fender switch for a short circuit. A. While operating the HPL fender switch mounted on the LH fender in the raise and then lower position, check between the connector: X-329 pin 1 wire 0.5 (RD/BL) and X-329 pin 3 wire 0.5 (RD/WH). If a short circuit is indicated, replace the HPL switch mounted on the LH fender. B. If the switch is okay, continue to step 6 6. Check the R/H HPL fender switch for a short circuit. A. While operating the HPL fender switch mounted on the RH fender in the raise and then lower position, check between the connector: X-330 pin 1 wire 0.5 (RD/BL) and X-330 pin 3 wire 0.5 (RD/WH). If a short circuit is indicated, replace the R/H HPL fender switch.

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B. If the switch is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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1010-Hitch height limit potentiometer - signal too low Control Module : CCU Possible failure modes: 1. Faulty connector 2. Faulty height limit control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the height limit control potentiometer in H9, ch 35. A. Turn the height limit control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 400 - 4600 mV, continue to step 2 B. If the values displayed are okay, while still in H9, ch. 35 wiggle the harness and the EDC control panel connector X-327, the connectors X-200 and X-210 of the controller wiring to check for an intermittent circuit. The values of ch 35 will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the height limit control potentiometer. A. Remove the EDC control panel and disconnect the connector X-327. While turning the height limit control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: X-327 pin 5 and X-327 pin 3 X-327 pin 6 and X-327 pin 3. If the resistances indicated are not between 90 - 360 ÎŠ (with slip control) and between 170 - 520 ÎŠ (without slip control), replace the control panel. B. If the EDC control panel is okay, continue to step 3 3. Check for a short to ground. A. Check between: X-327 pin 3 wire 0.5 (GY/BK) and ground X-327 pin 5 wire 0.5 (TO/WH) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 4 4. Check for an open circuit. A. Disconnect the connectors X-200 and X-210 of the controller. Check between: X-200 pin 23 wire 1.0 (BK/WH) and X-327 pin 6 wire 0.5 (BK/WH) X-210 pin 5 wire 0.5 (GY/BK) and X-327 pin 3 wire 0.5 (GY/BK) X-210 pin 17 wire 0.5 (TQ/WH) and X-327 pin 5 wire 0.5 (TQ/WH). If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1011-Hitch height limit potentiometer - signal too high Control Module : CCU Cause: HEIGHT LIMIT POTENTIOMETER SIGNAL TOO HIGH (SHORT TO + 12 V) Possible failure modes: 1. Faulty connector 2. Faulty height limit control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the height limit control potentiometer in H9, ch. 35. A. Turn the height limit control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 400 - 4600 mV, continue to step 2 B. If the values displayed are okay, while still in H9, ch. 35 wiggle the harness and the EDC control panel connector X-327, the connectors X-200 and X-210 of the controller wiring to check for an intermittent circuit. The values of ch 35 will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the height limit control potentiometer. A. Remove the EDC control panel and disconnect the connector X-327. While turning the height limit control knob fully clockwise and then fully counter clockwise, measure the resistance between: X-327 pin 5 and X-327 pin 3 X-327 pin 6 and X-327 pin 3. If the resistances indicated are not between 90 - 360 ÎŠ (with slip control) and between 170 - 520 ÎŠ (without slip control), replace the control panel. B. If the EDC control panel is okay, continue to step 3 3. Check for a short to + 8 V or + 12 V. A. Turn the ignition key switch ON. Measure the voltage, with the panel disconnected, between the connector X-327 pin 5 wire 0.5 (TQ/WH) and ground. If the voltage indicated is greater than + 5 V , repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V , continue to step 4 4. Check for a short circuit to positive. A. Measure the voltage between the connector: X-327 pin 3 wire 0.5 (GY/BK) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1012-Hitch drop rate potentiometer - signal too low Control Module : CCU Cause: DROP RATE POTENTIOMETER SIGNAL TOO LOW (SHORT OR OPEN CIRCUIT) Possible failure modes: 1. Faulty connector 2. Faulty drop rate control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the drop rate control potentiometer in H9, ch 34. A. Turn the drop rate control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 400 - 4600 mV, continue to step 2 B. If the values displayed are okay, while still in H9, ch. 34 wiggle the harness and the EDC control panel connector X-327, the connectors X-200 and X-210 of the controller wiring to check for an intermittent circuit. The values of ch 34 will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the drop rate control potentiometer. A. Remove the EDC control panel and disconnect the connector X-327. While turning the drop rate control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: X-327 pin 5 and X-327 pin 4, X-327 pin 6 and X-327 pin 4. If the resistances indicated are not between 90 - 360 ÎŠ (with slip control) and between 170 - 520 ÎŠ (without slip control), replace the EDC control panel. B. If the EDC control panel is okay, continue to step 3 3. Check for a short to ground. A. Check between (wire side): X-327 pin 4 wire 0.5 (YE/RD) and ground X-327 pin 5 wire 0.5 (TQ/WH) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 4 4. Check for an open circuit. A. Disconnect the connectors X-200 and X-210 of the controller. Check between: X-200 pin 23 wire 1.0 (BK/WH) and X-327 pin 6 wire 0.5 (BK/WH) X-210 pin 4 wire 0.5 (YE/RD) and X-327 pin 4 wire 0.5 (YE/RD) X-210 pin 17 wire 0.5 (TQ/WH) and X-327 pin 5 wire 0.5 (TQ/WH). If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1013-Hitch drop rate potentiometer - signal too high Control Module : CCU Cause: DROP RATE POTENTIOMETER SIGNAL TOO HIGH (SHORT TO + 12 VOLT) Possible failure modes: 1. Faulty connector 2. Faulty drop rate control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the drop rate control potentiometer in H9, ch. 34. A. Turn the slip control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 400 - 4600 mV, continue to step 2 B. If the values displayed are okay, while still in H9, ch. 34 wiggle the harness and the EDC control panel connector X-327, the connectors X-200 and X-210 of the controller wiring to check for an intermittent circuit. The values of ch 34 will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the drop rate control potentiometer. A. Remove the EDC control panel and disconnect the connector X-327. While turning the drop rate control knob fully clockwise and then fully counter clockwise, measure the resistance between: X-327 pin 5 and X-327 pin 4, X-327 pin 6 and X-327 pin 4. If the resistances indicated are not between 90 - 360 ÎŠ (with slip control) and between 170 - 520 ÎŠ (without slip control), replace the control panel. B. If the EDC control panel is okay, continue to step 3 3. Check for a short to + 8 V or + 12 V. A. Turn the Ignition key Switch ON. Measure the voltage, with the panel disconnected, between the connector X-327 pin 5 wire 0.5 (TQ/WH) and ground. If the voltage indicated is greater than + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 4 4. Check for a short circuit with positive voltage. A. Measure the voltage between the connector: X-327 pin 4 wire 0.5 (YE/RD) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1014-Right-hand draft pin sensor - signal too low Control Module : CCU Cause: R/H LOAD SENSING PIN SIGNAL TOO LOW (SHORT OR OPEN CIRCUIT) Possible failure modes: 1. Faulty connector 2. Faulty load sensing pin 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the right-hand load sensing pin connector X-332, transmission - cab main connector X-300 and the connectors X-200 and X-210 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the right-hand load sensing pin in H9, ch 11. A. Where possible, remove any implements to ensure the load sensing pins are not under any draft loading. If the value displayed is between 830 - 7680 mV, check for an intermittent circuit to the load sensing pin; repair or replace the harness as required. If the error re-occurs and no intermittent circuit is indicated, download the correct level of software. If the fault re-occurs, remove and replace the controller. B. If the value displayed in H9 channel 11 is not between 830 - 7680 mV, continue to step 3 3. Replace the load sensing pin. A. Turn the ignition key switch OFF. Remove and replace the load sensing pin (If a new pin is not available interchange the left and right hand load sensing pins). If the error is cleared, remove and replace the faulty sensing pin. B. If the error re-occurs, continue to step 4 4. Check for a short to ground. A. Disconnect the connector X-200 and X-210 the connectors X-331 and X-332 of both load sensing pins. Check between: X-332 pin 2 wire 1.0 (GY/GN) and ground X-332 pin 3 wire 1.0 (BY/BK) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for an open circuit. A. Check between: X-332 pin 1 wire 0.5 (BK/WH) and X-200 pin 23 wire 1.0 (BK/WH). X-332 pin 2 wire 1.0 (GY/GN) and X-210 pin 9 wire 1.0 (GY/GN) X-332 pin 3 wire 1.0 (GY/BK) and X-210 pin 25 wire 1.0 (GY/BL) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1015-Right-hand draft pin sensor - signal too high Control Module : CCU Cause: R/H LOAD SENSING PIN SIGNAL TOO HIGH (SHORT TO + 12 V) Possible failure modes: 1. Faulty connector 2. Faulty load sensing pin 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the right-hand load sensing pin connector X-332, transmission - cab main connector X-300 and the connectors X-200 and X-210 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the load sensing pin in H9, ch 11. A. Where possible, remove any implements to ensure the load sensing pins are not under any draft loading. If the value displayed is between 830 - 7680 mV, check for an intermittent circuit to the load sensing pin; repair or replace the harness as required. If the error re-occurs and no intermittent circuit is indicated, download the correct level of software. If the fault re-occurs, remove and replace the controller. B. If the value displayed in H9 channel 11 is not between 830 - 7680 mV, continue to step 3 3. Replace the load sensing pin. A. Turn the ignition key switch OFF. Remove and replace the load sensing pin (If a new pin is not available interchange the left and right hand load sensing pins). If the error is cleared, remove and replace the faulty sensing pin. B. If the error re-occurs, continue to step 4 4. Check for a short to + 12 V. A. Disconnect the connectors X-200 and X-210 and the connectors X-331 and X-332 of both load sensing pins. Turn the ignition key switch ON. Check between: X-332 pin 1 wire 1.0 (BK/WH) and ground X-332 pin 2 wire 1.0 (GY/GN) and ground X-332 pin 3 wire 1.0 (GY/BK) and ground If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1016-Left-hand draft pin sensor - signal too low Control Module : CCU Cause: L/H LOAD SENSING PIN SIGNAL TOO LOW (SHORT OR OPEN CIRCUIT) Possible failure modes: 1. Faulty connector 2. Faulty load sensing pin 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the left-hand load sensing pin connector X-331, transmission - cab main connector X-300 and the connectors X-200 and X-210 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the load sensing pin in H9, ch 10. A. Where possible, remove any implements to ensure the load sensing pins are not under any draft loading. If the value displayed is between 830 - 7680 mV, check for an intermittent circuit to the load sensing pin; repair or replace the harness as required. If the error re-occurs and no intermittent circuit is indicated, download the correct level of software. If the fault re-occurs, remove and replace the controller. B. If the value displayed in H9 channel 10 is not between 830 - 7680 mV, continue to step 3 3. Replace the load sensing pin. A. Turn the ignition key switch OFF. Remove and replace the load sensing pin (If a new pin is not available interchange the left and right hand load sensing pins). If the error is cleared, remove and replace the faulty sensing pin. B. If the error re-occurs, continue to step 4 4. Check for a short to ground. A. Disconnect the connectors X-200 and X-210 and the connectors X-331 and X-332 of both the load sensing pins. Check between: X-331 pin 2 wire 1.0 (YE/GN) and ground X-331 pin 3 wire 1.0 (GY/BL) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for an open circuit. A. Check between: X-331 pin 1 wire 1.0 (BK/WH) and X-200 pin 23 wire 1.0 (BK/WH) X-331 pin 2 wire 1.0 (YE/GN) and X-210 pin 10 wire 1.0 (YE/GN) X-331 pin 3 wire 1.0 (GY/BL) and X-210 pin 25 wire 1.0 (GY/BL). If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1017-Left-hand draft pin sensor - signal too high Control Module : CCU Cause: L/H LOAD SENSING PIN SIGNAL TOO HIGH (SHORT TO + 12 V) Possible failure modes: 1. Faulty connector 2. Faulty load sensing pin 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the left-hand load sensing pin connector X-331, transmission - cab main connector X-300 and the connectors X-200 and X-210 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the load sensing pin in H9, ch 10. A. Where possible, remove any implements to ensure the load sensing pins are not under any draft loading. If the value displayed is between 830 - 7680 mV, check for an intermittent circuit to the load sensing pin; repair or replace the harness as required. If the error re-occurs and no intermittent circuit is indicated, download the correct level of software. If the fault re-occurs, remove and replace the controller. B. If the value displayed in H9 channel 10 is not between 830 - 7680 mV, continue to step 3 3. Replace the load sensing pin. A. Turn the ignition key switch OFF. Remove and replace the load sensing pin (If a new pin is not available interchange the left and right hand load sensing pins). If the error is cleared, remove and replace the faulty sensing pin. B. If the error re-occurs, continue to step 4 4. Check for a short to + 12 V. A. Disconnect the connectors X-200 and X-210 and the connectors X-331 and X-332 of both load sensing pins. Turn the ignition key switch ON. Check between: X-331 pin 1 wire 1.0 (BK/WH) and ground. X-331 pin 2 wire 1.0 (YE/GN) and ground. X-331 pin 3 wire 1.0 (GY/BL) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1018-Draft pin sensors - both signals too low Control Module : CCU Cause: BOTH LOAD SENSING PINS DISCONNECTED Possible failure modes: 1. Faulty connector 2. Wiring harness faulty 3. Faulty controller Solution: 1. Check the transmission - cab main connector X-300, the connectors X-200 and X-210 of the controller and the connectors X-331 and X-332 of both load sensing pins. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Visually check the harness to both pins for any damage. A. If the harness is damaged, repair or replace as required. B. If no visible damage to the harness is indicated, continue to step 3 3. Check for an open circuit. A. Disconnect the connectors X-200 and X-210 of the controller and the connectors X-331 and X-332 of both load sensing pins. Check between: X-332 pin 1 wire 0.5 (BK/WH) and X-200 pin 23 wire 1.0 (BK/WH). X-332 pin 2 wire 1.0 (GY/GN) and X-210 pin 9 wire 1.0 (GY/GN) X-332 pin 3 wire 1.0 (GY/BK) and X-210 pin 25 wire 1.0 (GY/BL) X-331 pin 1 wire 1.0 (BK/WH) and X-200 pin 23 wire 1.0 (BK/WH) X-331 pin 2 wire 1.0 (YE/GN) and X-210 pin 10 wire 1.0 (YE/GN) X-331 pin 3 wire 1.0 (GY/BL) and X-210 pin 25 wire 1.0 (GY/BL) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1019-8 V reference voltage for draft pin sensors - voltage too low Control Module : CCU Cause: LOAD SENSING PIN VOLTAGE TOO LOW (SHORT OR OPEN CIRCUIT) Possible failure modes: 1. Faulty load sensing pin 2. Wiring harness faulty 3. Faulty controller Solution: 1. Check the + 8 V sensor supply in H9, ch 216. A. If the value displayed is between 7000 - 9000 mV, check for an intermittent circuit to the load sensing pin; repair or replace the harness as required. If the error re-occurs and no intermittent circuit is indicated, download the correct level of software. If the fault re-occurs, remove and replace the controller. B. If the value displayed is not between 7000 - 9000 mV, continue to step 2 2. Check for a short to ground. A. Disconnect the connectors X-331 and X-332 of both load sensing pins. Check between: X-331 pin 3 wire 1.0 (GY/BL) and ground X-332 pin 3 wire 1.0 (GY/BK) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 3 3. Check for an open circuit. A. Disconnect the connectors X-200 and X-210 of the controller. Check between: X-332 pin 3 wire 1.0 (GY/BK) and X-210 pin 25 wire 1.0 (GY/BL) X-332 pin 1 wire 0.5 (BK/WH) and X-200 pin 23 wire 1.0 (BK/WH) X-331 pin 3 wire 1.0 (GY/BL) and X-210 pin 25 wire 1.0 (GY/BLU) X-331 pin 1 wire 1.0 (BK/WH) and X-200 pin 23 wire 1.0 (BK/WH) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, continue to step 4 4. Replace the load sensing pin(s). A. Remove and replace the load sensing pin(s). B. If the error re-occurs, refit the old load sensing pins and download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1020-8 V reference voltage for draft pin sensors - voltage too high Control Module : CCU Cause: LOAD SENSING PIN VOLTAGE TOO HIGH (SHORT TO + 12 V) Possible failure modes: 1. Faulty connector 2. Faulty load sensing pin 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the + 8 V sensor supply in H9, ch 216. A. If the value displayed is between 7000 - 9000 mV, check for an intermittent circuit to the load sensing pin; repair or replace the harness as required. If the error re-occurs and no intermittent circuit is indicated, download the correct level of software. If the fault re-occurs, remove and replace the controller. B. If the value displayed is not between 7000 - 9000 mV, continue to step 2 2. Check for a short to + 12 V. A. Disconnect the connectors X-200 and X-210 of the controller and the connectors X-331 and X-332 of both load sensing pins. Turn the ignition key switch ON. Check between: X-332pin 3 wire 1.0 (GY/BK) and ground X-332 pin 2 wire 1.0 (GY/GN) and ground X-332 pin 1 wire 0.5 (BK/WH) and ground X-331 pin 3 wire 1.0 (GY/BL) and ground X-331 pin 2 wire 1.0 (YE/GN) and ground X-331 pin 1 wire 1.0 (BK/WH) and ground If a voltage is indicated, repair or replace the harness as required. B. If harness okay, continue to step 3 3. Replace the load sensing pin(s). A. Remove and replace the load sensing pin(s). B. If the error re-occurs, refit the old load sensing pins and download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1021-Hitch sensitivity control potentiometer - signal too low Control Module : CCU Cause: SENSITIVITY CONTROL POTENTIOMETER SIGNAL TOO LOW (SHORT OR OPEN CIRCUIT) Possible failure modes: 1. Faulty connector 2. Faulty draft sensitivity control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the draft sensitivity control potentiometer in H9, ch 36. A. Turn the draft sensitivity control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 400 - 4600 mV, continue to step 2 B. If the values displayed are okay, while still in H9, ch. 36 wiggle the harness and the EDC control panel connector X-327 and the controller harness connectors X-200 and X-210 to check for an intermittent circuit. The values of ch 36 will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the draft sensitivity control potentiometer. A. Remove the EDC control panel and disconnect the connector X-327. While turning the load sensitivity control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: X-327 pin 8 and X-327 pin 5 X-327 pin 8 and X-327 pin 6 If the resistances indicated are not between 90 - 360 ÎŠ (with slip control) and between 170 - 520 ÎŠ (without slip control), replace the EDC control panel. B. If the EDC control panel is okay, continue to step 3 3. Check for a short to ground. A. Check between: X-327 pin 5 wire 0.5 (TQ/WH) and ground X-327 pin 8 wire 0.5 (RD) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 4 4. Check for an open circuit. A. Disconnect the connectors X-200 and X-210 of the controller. Check between: X-200 pin 23 wire 1.0 (BK/WH) and X-327 pin 6 wire 0.5 (BK/WH) X-210 pin 6 wire 0.5 (RD) and X-327 pin 8 wire 0.5 (RD) X-210 pin 17 wire 1.0 (TQ/WH) and X-327 pin 5 wire 0.5 (TQ/WH) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1022-Hitch sensitivity control potentiometer - signal too high Control Module : CCU Cause: SENSITIVITY CONTROL POTENTIOMETER SIGNAL TOO HIGH (SHORT TO + 12 V) Possible failure modes: 1. Faulty connector 2. Faulty draft sensitivity control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the draft sensitivity control potentiometer in H9, ch 36. A. Turn the draft sensitivity control knob fully clockwise and then fully counter clockwise. If the values displayed are not between 400 - 4600 mV, continue to step 2 B. If the values displayed are okay, while still in H9, ch. 36 wiggle the harness and the EDC control panel connector X-327 and the controller harness connectors X-200 and X-210 to check for an intermittent circuit. The values of ch 36 will change if an intermittent circuit is indicated; Repair or replace as necessary. 2. Check the draft sensitivity control potentiometer. A. Remove the EDC control panel and disconnect the connector X-327. While turning the load sensitivity control knob fully clockwise and then fully counter clockwise, measure the resistance on the potentiometer panel side between: X-327 pin 8 and X-327 pin 5 X-327 pin 8 and X-327 pin 6 If the resistances indicated are not between 90 - 360 ÎŠ (with slip control) and between 170 - 520 ÎŠ (without slip control), replace the EDC control panel. B. If the EDC control panel is okay, continue to step 3 3. Check for a short to + 8 V or + 12 V. A. Turn the key start ON. Measure the voltage, with the panel disconnected, between the connector: X-327 pin 5 wire 0.5 (TQ/WH) and ground. If the voltage indicated is greater than + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 4 4. Check for a short circuit with positive voltage. A. Measure the voltage between the connector: X-327 pin 8 wire 0.5 (RD) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1023-Hitch electronic control panel - disconnected Control Module : CCU Possible failure modes: 1. Faulty connector 2. Faulty potentiometer panel 3. Wiring harness faulty Solution: 1. Check the EDC potentiometer panel connector X-327, the connectors X-200 and X-210 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Visually check the harness to the potentiometer panel for any damage. A. If the harness is damaged, repair or replace as required. B. If the harness is not damaged, continue to step 3 3. Check all harness connectors are connected. A. If any connectors are disconnected, connect the connectors as required. B. If the harness is okay, remove and replace the EDC control panel.

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1024-Hitch position sensor - not calibrated Control Module : CCU Cause: CALIBRATE THE HYDRAULIC LIFT Possible failure modes: 1. Replace arm lift potentiometer 2. Replace solenoid valve 3. Replace control unit 4. After deleting the memory in H8 Solution: 1. Perform the hydraulic lift calibration procedure NOTE: For the calibration procedure, please refer to the HH menu, RI, H1.

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1025-Hitch position control potentiometer - signal too low Control Module : CCU Cause: POSITION CONTROL POTENTIOMETER CONTROL VOLTAGE TOO LOW (SHORT OR OPEN CIRCUIT) Possible failure modes: 1. Faulty connector 2. Faulty position control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the position control potentiometer for any damage. A. If the potentiometer is damaged, remove and replace the potentiometer. B. If the potentiometer is okay, continue to step 2 2. Check the position control potentiometer in H9, Channel 33. A. Fully lower and then raise the position control potentiometer. If the values displayed are not between 400 4600 mV, continue to step 3 B. If the values displayed are okay, while still in H9 Channel 33, wiggle the harness and the control unit connector X-200 and X-210 and the EDC control panel connector X-326 to check for an intermittent circuit. Channel 33 values will change if an intermittent circuit is detected; repair or replace as necessary. 3. Check the position control potentiometer. A. Disconnect the connector X-326 of the EDC control panel. While moving the position control potentiometer from the minimum to maximum position, measure the resistance between the component side of connector: X-326 pin A and X-326 pin C X-326 pin A and X-326 pin D If the indicated values are not between 100 - 600 ÎŠ, remove and replace the EDC control unit. B. If the EDC control unit is okay, continue to step 4 4. Check for a short to ground. A. Check between: X-326 pin A wire 0.5 (BL/RD) and ground X-326 pin C wire 0.5 (TQ/WH) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Disconnect the connectors X-200 and X-210 of the controller. Check the EDC control panel for an open circuit. A. Check between: X-326 pin A wire 0.5 (BL/RD) and X-210 pin 3 wire 0.5 (BL/RD) X-326 pin C wire 0.5 (TQ/WH) and X-210 pin 17 wire 0.5 (TQ/WH) X-326 pin D wire 0.5 (BK/WH) and X-200 pin 23 wire 1.0 (BK/WH). If an open circuit is indicated, remove and replace the EDC control panel. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1026-Hitch position control potentiometer - signal too high Control Module : CCU Cause: POSITION CONTROL POTENTIOMETER CONTROL VOLTAGE TOO HIGH (SHORT TO + 12 V) Possible failure modes: 1. Faulty connector 2. Faulty position control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the position control potentiometer for any damage. A. If the potentiometer is damaged, remove and replace the potentiometer. B. If the potentiometer is okay, continue to step 2 2. Check the position control potentiometer in H9, Channel 33. A. Fully lower and then raise the position control potentiometer. If the values displayed are not between 400 4600 mV, continue to step 3 B. If the values displayed are okay, while still in H9 Channel 33, wiggle the harness and the control unit connector X-200 and X-210 and the EDC control panel connector X-326 to check for an intermittent circuit. Channel 33 values will change if an intermittent circuit is detected; repair or replace as necessary. 3. Check the position control potentiometer. A. Disconnect the connector X-326. While moving the position control potentiometer from the minimum to maximum position, measure the resistance between the component side of connector: X-326 pin A and X-326 pin C X-326 pin A and X-326 pin D If the indicated values are not between 100 - 600 ÎŠ, remove and replace the EDC control unit. B. If the EDC control unit is okay, continue to step 4 4. Check for a short to + 8 V or + 12 V. A. Turn the key start ON. Measure the voltage between the connector: X-326 pin C wire 0.5 (TQ/WH) and ground. If the voltage indicated is greater than + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 5 5. Check for a short circuit with positive voltage A. Measure the voltage between the connector: X-326 pin A wire 0.5 (BL/RD) and ground. If a voltage is indicated, remove and replace the EDC control panel. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1027-Hitch position sensor - signal too low Control Module : CCU Possible failure modes: 1. Faulty connector 2. Faulty lift arm position sensing control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the lift arm position sensing potentiometer and itâ&#x20AC;&#x2122;s linkage for any damage. A. If the potentiometer or linkage is damaged, repair or replace as required. B. If the potentiometer and the linkage is okay, continue to step 2 2. Check the lift arm position sensing potentiometer in H9, Channel 91. A. Fully lower then raise the arms of the hydraulic lift (check that the vertical tie rods of the quick coupler do not limit the movement of the arms). If the values displayed are not between 125 - 4640 mV, continue to step 3 B. If the values displayed are okay, while still in H9 channel 91, wiggle the harness, the lift arm position potentiometer connector X-328 , the transmission - cab main connector X-300 and the controller connectors X-200 and X-210 to check for an intermittent circuit. Channel 91 values will change if an intermittent circuit is detected; repair or replace as necessary. 3. Check the lift arm position sensing potentiometer. A. Disconnect the connector X-328 and remove the potentiometer. While turning the potentiometer, measure the resistance between the component side of connector: X-328 pin 2 and X-328 pin 3 X-328 pin 2 and X-328 pin 1. If the indicated resistances are not within the range between 1000 - 4000 ÎŠ, replace the lift arm position sensing potentiometer. B. If the values are okay, refit the potentiometer and continue to step 4 4. Check for a short to ground. A. Check between (wire side): X-328 pin 2 wire 1.0 (GY/WH) and ground X-328 pin 3 wire 1.0 (TQ/WH) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for an open circuit. A. Disconnect the connector X-200 and X-210 of the controller. Check between: X-328 pin 1 wire 1.0 (BK/WH) and X-200 pin 23 wire 1.0 (BK/WH) X-328 pin 2 wire 1.0 (GY/WH) and X-210 pin 2 wire 1.0 (GY/WH) X-328 pin 3 wire 1.0 (TQ/WH) and X-210 pin 17 wire 0.5 (TQ/WH). If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1028-Hitch position sensor - signal too high Control Module : CCU Cause: LIFT ARM POSITION SENSING CONTROL VOLTAGE HIGH (SHORT TO + 12 V) Possible failure modes: 1. Faulty connector 2. Faulty lift arm position sensing control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the lift arm position sensing potentiometer and itâ&#x20AC;&#x2122;s linkage for any damage. A. If the potentiometer or linkage is damaged, repair or replace as required. B. If the potentiometer and the linkage is okay, continue to step 2 2. Check the lift arm position sensing potentiometer in H9, Channel 91. A. Fully lower then raise the arms of the hydraulic lift (check that the vertical tie rods of the quick coupler do not limit the movement of the arms). If the values displayed are not between 125 - 4640 mV, continue to step 3 B. If the values displayed are okay, while still in H9 channel 91, wiggle the harness, the lift arm position potentiometer connector X-328 , the transmission - cab main connector X-300 and the controller connectors X-200 and X-210 to check for an intermittent circuit. Channel 91 values will change if an intermittent circuit is detected; repair or replace as necessary. 3. Check the lift arm position sensing potentiometer. A. Disconnect the connector X-328 and remove the potentiometer. While turning the potentiometer, measure the resistance between the component side of connector: X-328 pin 2 and X-328 pin 3 X-328 pin 2 and X-328 pin 1. If the indicated resistances are not within the range between 1000 - 4000 ÎŠ, replace the lift arm position sensing potentiometer. B. If the values are okay, refit the potentiometer and continue to step 4 4. Check for a short to + 8 V or + 12 V. A. Turn the Ignition key Switch ON. Measure the voltage between the connector: X-328 pin 3 wire 1.0 (TQ/WH) and ground. If the voltage indicated is greater than + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 5 5. Check for a short circuit to a positive voltage A. Measure the voltage between the connector: X-328 pin 2 wire 1.0 (GY/WH) and ground. If a voltage is indicated, remove and replace the EDC control panel. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1029-Hitch control solenoid valves - disconnected Control Module : CCU Cause: HYDRAULIC CONTROL VALVE DISCONNECTED Possible failure modes: 1. Faulty connector 2. Wiring harness faulty 3. Faulty hydraulic control valve solenoid 4. Faulty controller Solution: 1. Check for other fault codes being displayed. A. If any other error code is displayed, continue to these tests. B. If no other error code is displayed, continue to step 2 2. Check the hydraulic control valve solenoid connectors X-334 and X-335 , the transmission - cab main connector X-300 and the connectors X-200 and X-220 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3 3. Visibly check the harness any damage. A. Check the harness from the controller connectors X-200 and X-220 to the hydraulic control valve connectors X-334 and X-335 via the main connector X-300 for damage. If damage to the harness is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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1030-Hitch electronic control panel - ground disconnected Control Module : CCU Cause: BREAK IN THE GROUND CIRCUIT Possible failure modes: 1. Faulty connector 2. Wiring harness faulty 3. Faulty controller Solution: 1. Check for other fault codes being displayed. A. If any other error code is displayed, continue to these tests. B. If no other error code is displayed, continue to step 2 2. Check the controller connector X-200 , transmission - cab main connector X-300 , clutch pedal potentiometer connector X-322 , oil temperature sensor connector X-316 , theoretical speed sensor connector X-309, EDC mouse connector X-326 , arms lift potentiometer connector X-328, lift potentiometer panel connector X-327, shuttle lever connector X-318 , and the right and left draft sensing pins X-331 and X-332 . A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3 3. Check for an open circuit. A. Disconnect the connectors X-200, X-318, X-326, X-322, X-316, X-309, X-328, X-327, X-331 and X-332. Check between: X-200 pin 23 wire 1.0 (BK/WH) and X-326 pin D wire 0.5 (BK/WH) X-200 pin 23 wire 1.0 (BK/WH) and X-322 pin 1 wire 0.5 (BK/WH) X-200 pin 23 wire 1.0 (BK/WH) and X-316 pin A wire 1.0 (BK/WH) X-200 pin 23 wire 1.0 (BK/WH) and X-309 pin 3 wire 1.0 (BK/WH) X-200 pin 23 wire 1.0 (BK/WH) and X-328 pin 1 wire 1.0 (BK/WH) X-200 pin 23 wire 1.0 (BK/WH) and X-327 pin 6 wire 0.5 (BK/WH) X-200 pin 23 wire 1.0 (BK/WH) and X-332 pin 1 wire 0.5 (BK/WH) X-200 pin 23 wire 1.0 (BK/WH) and X-331 pin 1 wire 1.0 (BK/WH) X-200 pin 23 wire 1.0 (BK/WH) and X-318 pin 8 wire 1.0 (BK/WH) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1031-Chassis harness - disconnected Control Module : CCU Possible failure modes: 1. Faulty connector 2. Wiring harness faulty 3. Faulty controller Solution: 1. Check the chassis harness connector X-300 . A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the chassis harness connector is okay, continue to step 2 2. Visually check the chassis harness for any damage. A. If the harness is damaged, repair or replace as required. B. If harness okay, continue to step 3 3. Check for other fault codes being displayed. A. If any other error code is displayed, continue to these tests. B. If no other error codes are displayed, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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1032-Hitch draft control potentiometer - signal too high Control Module : CCU Cause: DRAFT CONTROL POTENTIOMETER CONTROL VOLTAGE HIGH (SHORT TO + 12 V) Possible failure modes: 1. Faulty connector 2. Faulty draft control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the draft control potentiometer for any damage. A. If the potentiometer is damaged, remove and replace the potentiometer. B. If the potentiometer is okay, continue to step 2 2. Check the draft control potentiometer in H9 Channel 40. A. Fully lower and then raise the draft control potentiometer. If the values displayed are not between 400 - 4600 mV, continue to step 3 B. If the values displayed are okay, while still in H9 Channel 40, wiggle the harness and the control unit connector X-200 and X-210 and the EDC control panel connector X-326 to check for an intermittent circuit. Channel 40 values will change if an intermittent circuit is detected; Repair or replace as necessary. 3. Check the draft control potentiometer. A. Disconnect the connector X-326. While moving the position control potentiometer from the minimum to maximum position, measure the resistance between the component side of connector: X-326 pin B and X-326 pin C X-326 pin B and X-326 pin D If the indicated values are not between 100 - 600 ÎŠ, remove and replace the EDC control unit. B. If the EDC control unit is okay, continue to step 4 4. Check for a short to + 8 V or + 12 V. A. Turn the key start ON. Measure the voltage between the connector: X-326 pin C wire 0.5 (TQ/WH) and ground. If the voltage indicated is greater than + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 5 5. Check for a short circuit with positive voltage A. Measure the voltage between the connector: X-326 pin B wire 0.5 (GY/BK) and ground. If a voltage is indicated, remove and replace the EDC control panel. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1033-Hitch draft control potentiometer - signal too low Control Module : CCU Cause: DRAFT CONTROL POTENTIOMETER CONTROL VOLTAGE LOW (SHORT OR OPEN CIRCUIT) Possible failure modes: 1. Faulty connector 2. Faulty draft control potentiometer 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the draft control potentiometer for any damage. A. If the potentiometer is damaged, remove and replace the potentiometer. B. If the potentiometer is okay, continue to step 2 2. Check the position control potentiometer in H9, Channel 40. A. Fully lower and then raise the position control potentiometer. If the values displayed are not between 400 4600 mV, continue to step 3 B. If the values displayed are okay, while still in H9 Channel 40, wiggle the harness and the control unit connector X-200 and X-210 and the EDC control panel connector X-326 to check for an intermittent circuit. Channel 40 values will change if an intermittent circuit is detected; Repair or replace as necessary. 3. Check the draft control potentiometer. A. Disconnect the connector X-326 of the EDC control panel. While moving the position control potentiometer from the minimum to maximum position, measure the resistance between the component side of connector: X-326 pin B and X-326 pin C X-326 pin B and X-326 pin D If the indicated values are not between 100 - 600 ÎŠ, remove and replace the EDC control unit. B. If the EDC control unit is okay, continue to step 4 4. Check for a short to ground. A. Check between: X-326 pin B wire 0.5 (GY/BK) and ground X-326 pin C wire 0.5 (TQ/WH) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Disconnect the connectors X-200 and X-210 of the controller. Check the EDC control panel for an open circuit. A. Check between: X-326 pin B wire 0.5 (GY/BK) and X-210 pin 8 wire 0.5 (GY/BK) X-326 pin C wire 0.5 (TQ/WH) and X-210 pin 17 wire 0.5 (TQ/WH) X-326 pin D wire 0.5 (BK/WH) and X-200 pin 23 wire 1.0 (BK/WH) If an open circuit is indicated, remove and replace the EDC control panel. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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1049-CAN-Bus signal fault - transmission output speed Control Module : CCU Cause: The wheel speed signal has not been received via the CAN network Possible failure modes: 1. Faulty connector 2. Faulty CAN network 3. Faulty wheel speed sensor 4. Wiring harness faulty 5. Faulty central control unit ( CCU) Solution: 1. Check for other CAN network related error codes displayed. A. If other error codes for the CAN network are displayed, continue to these tests. B. If no other error codes for the CAN network are displayed, continue to step 2 2. Check the wheel speed sensor connector X-309, the controller connectors X-200 and X-210 and X-240 and the transmission cab main connector X-300 of the in-line harness. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3 3. Check for + 12 Volts. A. Disconnect connector X-309. Turn the ignition key switch ON. Measure the voltage between connector X-309 pin 1, wire 1.0 (WH) and ground. If approximately + 12 Volts is not indicated, repair or replace the harness as required. B. If approximately + 12 Volts is indicated, continue to step 4 4. Check for an open ground circuit. A. Check between connector X-309 pin 3, wire 1.0 (BK/WH) and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connector X-240. Check between connector X-240 pin 22, wire 1.0 (OR/BL) and connector X-309 pin 2, wire 1.0 (OR/BL). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 6 6. Check for a short to ground. A. Check between connector X-309 pin 2, wire 0.5 (OR/BL) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, remove and replace the wheel speed sensor. If the fault is still present, download the correct level of software. If the fault re-occurs, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14) Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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1053-5 V reference voltage for Electronic Draft Control (EDC) voltage too high Control Module : CCU Cause: Controller 5 V reference shorted to a positive voltage. Possible failure modes: 1. Wiring fault 2. Central control unit ( CCU) fault Solution: 1. Check for other fault codes being displayed. A. If any other error code is displayed, continue to these tests. B. If no other error code is displayed, continue to step 2 2. Check the + 5 V sensor supply reference in H9, ch 217. A. If the value displayed is not between 4200 mV and 5800 mV, continue to step 3 B. If the value displayed is between 4200 mV and 5800 mV, while still in H9, ch 217 check for an intermittent circuit by wiggling the : harness central control unit ( CCU) connectors X-200 and X-210 EDC control panel connector X-327 rockshaft (rear hitch) position sensor connector X-328 shuttle lever connector X-318 low and high range switch connectors X-199 and X-308 4/5 syncroniser position sensor connector X-194 forward/reverse syncroniser position sensor connector X-195 transmission oil pressure sensor connector X-196 clutch pedal potentiometer connector X-322 rear power take-off (PTO) speed switch connector X-352 park brake switch connector X-315 electro hydraulic remote (EHR) encoder connector X-338 inline harness connector X-300 Channel 217 values will change if an intermittent circuit is detected. If an intermittent fault is identified, repair or replace as necessary. C. If an intermittent fault is not identified, continue to step 3 3. Check for a short to + 8 V or + 12 V. A. Disconnect the connector of the central control unit ( CCU) X-210. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: X-210 pin 17, wire 1.0 (TQ/WH) and ground. If a voltage is indicated, repair or replace the harness as required. B. If no voltage is indicated, download the correct level of software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

03 04 14 15

(55.100.DP-C.20.E.03) (55.100.DP-C.20.E.04) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15)

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1054-5 V reference voltage for Electronic Draft Control (EDC) voltage too low Control Module : CCU Possible failure modes: 1. Wiring fault 2. Central control unit ( CCU) fault Solution: 1. Check for other fault codes being displayed. A. If any other error code is displayed, continue to these tests. B. If no other error code is displayed, continue to step 2 2. Check the + 5 V sensor supply reference in H9, ch 217. A. If the value displayed is not between 4200 mV and 5800 mV, continue to step 3 B. If the value displayed is between 4200 mV and 5800 mV, while still in H9, ch 217 check for an intermittent circuit by wiggling the : harness central control unit ( CCU) connectors X-200 and X-210 EDC control panel connector X-327 rockshaft (rear hitch) position sensor connector X-328 shuttle lever connector X-318 low and high range switch connectors X-199 and X-308 4/5 syncroniser position sensor connector X-194 forward/reverse syncroniser position sensor connector X-195 transmission oil pressure sensor connector X-196 clutch pedal potentiometer connector X-322 rear power take-off (PTO) speed switch connector X-352 park brake switch connector X-315 electro hydraulic remote (EHR) encoder connector X-338 inline harness connector X-300 Channel 217 values will change if an intermittent circuit is detected. If an intermittent fault is identified, repair or replace as necessary. C. If an intermittent fault is not identified, continue to step 3 3. Check for a short to ground. A. Disconnect the connector X-210. Check between the connector X-210 pin 17 wire 1.0 (TQ/WH) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

03 04 14 15

(55.100.DP-C.20.E.03) (55.100.DP-C.20.E.04) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15)

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1063-Lower solenoid valve - open circuit Control Module : CCU Possible failure modes: 1. Faulty connector 2. Faulty EDC valve lower solenoid 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the EDC valve lowering solenoid connector X-335, the transmission - cab main connector X-300 and the connectors X-200 and X-220 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the EDC valve lower solenoid. A. Disconnect the connector X-335 of the EDC valve lowering solenoid valve. Measure the resistance between the terminals of the solenoid valve. If the resistance indicated is not approximately 2 ÎŠ, remove and replace the EDC valve lower solenoid. B. If the solenoid valve is okay continue to step 3 3. Check for a short to ground. A. Check between the connector: X-335 pin 1 wire 1.0 (GN/WH) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to ground. A. Disconnect the connector X-220 of the controller. Check between the connector: X-335 pin 2 wire 1.0 (GN/YE) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for an open circuit. A. Disconnect the connector X-200 of the controller. Check between: X-335 pin 2 wire 1.0 (GN/YE) and X-220 pin 5 wire 1.0 (GN/YE) X-335 pin 1 wire 1.0 (GN/WH) and X-200 pin 12 wire 1.0 (GN/WH) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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1064-Raise solenoid valve - open circuit Control Module : CCU Cause: EDC HYDRAULIC VALVE RAISE SOLENOID OPEN CIRCUIT Possible failure modes: 1. Faulty connector 2. Faulty EDC valve raise solenoid 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the EDC valve raising solenoid connector X-334, the transmission - cab main connector X-300 and the connectors X-200 and X-220 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the EDC valve raise solenoid. A. Disconnect the connector X-334 of the EDC valve lifting solenoid valve. Measure the resistance between the terminals of the solenoid valve. If the resistance indicated is not approximately 2 ÎŠ, remove and replace the EDC valve lower solenoid. B. If the solenoid valve is okay, continue to step 3 3. Check for a short to ground. A. Check between the connector X-334 pin 1 wire 1.0 (BK/WH) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to ground. A. Disconnect the connector X-200 of the controller. Check between the connector X-334 pin 2 wire 1.0 (GN/WH) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for an open circuit. A. Disconnect the connector X-220 of the controller. Check between: X-334 pin 2 wire 1.0 (GN/WH) and X-220 pin 4 wire 1.0 (GN/WH) X-334 pin 1 wire 1.0 (BK/WH) and X-200 pin 5 wire 1.0 (BK/WH). If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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1065-Lower solenoid valve - short circuit to battery Control Module : CCU Cause: EDC HYDRAULIC VALVE LOWER SOLENOID SHORT CIRCUIT Possible failure modes: 1. Faulty connector 2. Faulty EDC valve lower solenoid 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the EDC valve lowering solenoid connector X-335, the transmission - cab main connector X-300 and the connectors X-200 and X-220 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the EDC valve lower solenoid. A. Disconnect the connector X-335 of the EDC valve lowering solenoid valve. Measure the resistance between the terminals of the solenoid valve. If the resistance indicated is not approximately 2 ÎŠ, remove and replace the EDC valve lower solenoid. B. If the solenoid valve is okay, continue to step 3 3. Check for a short circuit with positive voltage. A. Turn the ignition key switch ON. Measure the voltage between the connector: X-335 pin 2 wire 1.0 (GN/YE) and ground If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 4 4. Check for a short circuit with positive voltage. A. Turn the Ignition Key Switch OFF. Disconnect the connector X-200 of the controller. Turn the ignition key switch ON. Measure the voltage between the connector: X-335 pin 1 wire 1.0 (GN/WH) and ground If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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1066-Raise solenoid valve - short circuit to battery Control Module : CCU Cause: EDC HYDRAULIC VALVE RAISE SOLENOID SHORT CIRCUIT Possible failure modes: 1. Faulty connector 2. Faulty EDC valve raise solenoid 3. Wiring harness faulty 4. Faulty controller Solution: 1. Check the EDC valve raising solenoid connector X-334, the transmission - cab main connector X-300 and the connectors X-200 and X-220 of the controller. A. Ensure the connectors are connected and not damaged, that the pins are in the correct position and the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the EDC valve raise solenoid. A. Disconnect the connector X-334 of the EDC valve lifting solenoid valve. Measure the resistance between the terminals of the solenoid valve. If the resistance indicated is not approximately 2 ÎŠ, remove and replace the EDC valve lower solenoid. B. If the solenoid valve is okay, continue to step 3 3. Check for a short circuit with positive voltage. A. Turn the ignition key switch ON. Measure the voltage between the connector: X-334 pin 2 wire 1.0 (GN/WH) and ground. If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 4 4. Check for a short circuit with positive voltage. A. Turn the ignition key switch OFF. Disconnect the connector X-200 of the controller. Turn the ignition key switch ON. Measure the voltage between the connector: X-334 pin 1 wire 1.0 (BK/WH) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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1067-Supply voltage for hitch control solenoid valves - voltage too low Control Module : CCU Cause: EDC CONTROL VALVE SUPPLY VOLTAGE LOW Possible failure modes: 1. Wiring harness faulty 2. Faulty controller Solution: 1. Check the + 12 V reference voltage in H9, ch 207. A. If the value displayed is between 9000 - 16000 mV, continue to test for error codes 1063 - Lower solenoid valve - open circuit, 1064 - Raise solenoid valve - open circuit, 1065 - Lower solenoid valve - short circuit to battery, and 1066 - Raise solenoid valve - short circuit to battery. B. If the value displayed is not between 9000 - 16000 mV, continue to step 2 2. Check for + 12 V at fuse F-009 ( 5 A). A. Turn the ignition key switch ON. Measure the voltage at fuse F-009 ( 5 A). If the voltage indicated is approximately + 12 V, continue to step 3 B. If the voltage indicated is not okay, check the supply from the battery to fuse F-009 ( 5 A). 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect the connector X-200 of the controller. Check between the connector: X-200 pin 20 wire 1.0 (BK/YE) and F-009 ( 5 A) wire 1.0 (BK/YE). If an open circuit is indicated,repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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1068-Electronic Draft Control (EDC) - calibration fault Control Module : CCU Cause: HEIGHT LIMIT CALIBRATION ERROR Possible failure modes: 1. Calibration was done incorrectly Solution: 1. Turn the height limit control to the maximum height position when performing the hydraulic lift calibration procedure. NOTE: When the cause of the fault code has been rectified, clear the fault code and test the system for normal operation. NOTE: If the height limit control has not been turned fully clockwise to the maximum height position, this error code will be displayed.

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Electrical systems - FAULT CODES

1070-Electronic Draft Control (EDC) - ram configuration not set Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Hydraulic ram configuration has not been set. Solution: 1. Configure the hydraulic ram(s). A. Using the H3, Channel 1, set the hydraulic ram option for the correct ram configuration on the machine: ‘A r0’ or ‘b r0’ (one internal ram) ‘A r1’ or ‘b r1’ (one internal ram and one external ram) ‘A r2’ or ‘b r2’ (one internal ram and two external ram’s)

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Electrical systems - FAULT CODES

2001-Shuttle too fast Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: The shuttle lever was moved to forward or reverse too fast. Possible failure modes: 1. Shuttle lever moved into forward or reverse too fast Solution: 1. Shift to neutral to re-enable the transmission and shift back to forward or reverse. A. If error code 2001is not displayed, test the system for normal operation. B. If error code 2001 is still displayed, check for other error codes being displayed and continue to these test.

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Electrical systems - FAULT CODES

2006-Radar sensor - disconnected or speed too low Control Module : CCU Possible failure modes: 1. Faulty connectors 2. Fuse F-009 ( 5 A) faulty 3. Radar faulty 4. Wiring fault 5. Central control unit ( CCU) fault Solution: 1. Check the connector of the radar X-333, the main cab-transmission connector X-188 and the connector of the control unit ( CCU) X-210. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the radar power supply. A. Disconnect the connector of the radar X-333, turn the ignition key switch ON, check whether + 12 V is indicated on the connector X-333 pin 3 wire 1.0 (BK/YE). If + 12 V is indicated, continue to 3 B. If + 12 V is not indicated, check fuse F-009.If the fuse is okay, repair or replace the harness as required. 3. Check for an open circuit. A. Disconnect the connector of the control unit ( CCU) X-210. Check between the connector: X-210 pin 19 wire 1.0 (BR/YE), and X-333 pin 4 wire 1.0 (BR/YE) X-210 pin 33 wire 1.0 (BK/WH), and X-333 pin 1wire 1.0 (BK/WH).If an open circuit is indicated, repair or replace the harness as required. B. Check between the connector: X-333 pin 2 wire 1.0 (BK) and ground.If an open circuit is indicated, repair or replace the harness as required. C. Turn the ignition key switch OFF, check whether + 12 V is indicated on the connector X-333 pin 4 wire 1.0 (BR/ YE)If an open circuit is indicated, repair or replace the harness as required. If an open circuit is not indicated, continue to 4 4. Check for a short to ground. A. Check between the connector: X-333 pin 1, wire 1.0 (BK/WH) and ground. X-333 pin 3 wire 1.0 (BK/YE) and ground. X-333 pin 4 wire 1.0 (BR/YE) and ground. If a short to ground is indicated, repair or replace the harness as required. If a short to ground is not indicated, continue to 5 5. Check the position of the radar. A. If the radar is pointing at the tractor wheel or excessively vibrating, point the radar at the ground and tighten the fixings. B. If the radar mounting and position is okay, remove and replace the radar assembly.

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C. If the error is still present, download the correct level of software. If the error is repeated, remove and replace the control unit ( CCU).

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Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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2011-Clutch pedal sensor - signal too low Control Module : CCU Cause: Short to ground or open circuit between the clutch pedal potentiometer and the central control unit ( CCU), or the potentiometer is faulty. Possible failure modes: If the error code occurs while driving it will disable the transmission. Cycling the shuttle lever will re-enable the transmission. The tractor may be used with the shuttle lever. If the clutch pedal is depressed the transmission will be disabled again until the shuttle lever has been cycled. 1. Faulty connectors 2. Clutch pedal potentiometer fault 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the clutch pedal potentiometer in H9, Channel 48. A. Cycle clutch pedal. If the values displayed do not change continuously between 220 - 4840 mV, continue to step 2 B. If the values displayed are okay, while still in H9 channel 48, wiggle the harness, the clutch pedal potentiometer connector X-322 and the connectors of the control unit ( CCU) X-230, X-200 and X-210 to check for an intermittent circuit. Channel 48 values will change if an intermittent circuit is indicated.Repair or replace as necessary. 2. Check connectors X-322, X-230, X-200 and X-210. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3 3. Check the clutch pedal potentiometer. A. Disconnect the connector X-322. While operating the clutch pedal, measure the resistance between the component side of connector: X-322 pin 2 and pin 3 must indicate between 900 立 and 3700 立 X-322 pin 2 and pin 1 must indicate between 3700 立 and 900 立. If the indicated resistances are not okay, remove and replace the clutch pedal potentiometer. B. If the clutch pedal potentiometer is okay, continue to step 4 4. Check for an open circuit. A. Disconnect the connector X-230, X-200 and X-210. Check between: X-322 pin 1, wire 0.5 (BK/WH) and X-200 pin 23, wire 1.0 (BK/WH) X-322 pin 2, wire 0.5 (WH) and X-230 pin 7, wire 0.5 (WH) X-322 pin 3, wire 0.5 (TQ/WH) and X-210 pin 17, wire 0.5 (TQ/WH). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue with step 5 5. Check for a short to ground. A. Check between the connector: X-322 pin 2, wire 0.5 (WH) and ground. If a short to ground is indicated, repair or replace the harness as required.

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B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit ( CCU).

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14) Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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2012-Clutch pedal sensor - signal too high Control Module : CCU Context: Cause: Short to ground or open circuit between the clutch pedal potentiometer and the central control unit ( CCU), or the potentiometer ground is an open circuit or the potentiometer is faulty. Effects: If the error code occurs while driving it will disable the transmission. Cycling the shuttle lever will re-enable the transmission. The tractor may be used with the shuttle lever. If the clutch pedal is depressed the transmission will be disabled again until the shuttle lever has been cycled. Possible failure modes: 1. Faulty connectors 2. Clutch pedal potentiometer fault 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the clutch pedal potentiometer in H9, Channel 48. A. Cycle clutch pedal. If the values displayed do not change continuously between 220 - 4840 mV, continue to step 2 B. If the values displayed are okay, while still in H9 channel 48, wiggle the harness, the clutch pedal potentiometer connector X-322 and the connectors of the control unit ( CCU) X-200, X-210 and X-230 to check for an intermittent circuit. Channel 48 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check connectors X-322, X-200, X-210 and X-230. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3 3. Check the clutch pedal potentiometer. A. Disconnect the connector X-322. While operating the clutch pedal, measure the resistance between the component side of connector: X-322 pin 2 and pin 3 must indicate between 900 Ω and 3700 Ω X-322 pin 2 and pin 1 must indicate between 3700 Ω and 900 Ω. If the indicated resistances are not okay, remove and replace the clutch pedal potentiometer. B. If the clutch pedal potentiometer is okay, continue to step 4 4. Check for a short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between connector: X-322 pin 2, wire 0.5 (WH) and ground X-322 pin 1, wire 0.5 (BK/WH) and ground. If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 5 5. Check for a short to + 8 V or + 12 V. A. With the ignition key switch ON. Measure the voltage between the connector: X-322 pin 3, wire 0.5 (TQ/WH) and ground. If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. 47538922 29/05/2013

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B. If the voltage indicated is approximately + 5 V, continue to step 6 6. Check for an open ground circuit. A. Turn ignition key switch to OFF position. Check between: X-322 pin 1, wire 0.5 (BK/WH) and ground. If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit ( CCU).

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14) Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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2016-Creeper solenoid error Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Failure to engage creeper gear Possible failure modes: 1. Faulty connector 2. Faulty creeper solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the creeper solenoid connector X-183, the controller connector X-240 and the inline harness connector X-188. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the creeper solenoid for short to ground. A. Disconnect connector X-183. Check between the component side of connector: X-183 pin 1 and ground X-183 pin 2 and ground If short to ground is indicated, remove and replace the creeper solenoid. B. If a short to ground is not indicated, continue to step 3 3. Check for short to ground. A. Disconnect connector X-240. Check between connector: X-183 pin 1 (GN) and ground X-183 pin 2 (GN/BK) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to +Ve Voltage. A. Turn the keystart ON. check between connector: X-183 pin 1 (GN) and ground X-183 pin 2 (GN/BK) and ground If a short to +Ve voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2024-At least one synchroniser require calibration Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled. Possible failure modes: 1. Transmission not calibrated 2. Faulty controller Solution: 1. Check if the transmission was calibrated, for further information refer to Semi-Powershift transmission - Calibrate (21.111). A. If the transmission was not calibrated after a replacement of the controller, or after using H8, clear the Electrical Erasable Programmable Read Only Memory (EEPROM), and perform the transmission calibration procedure. B. If the transmission was calibrated, download the correct level of software and re-perform the calibration procedure. If the fault re-occurs again, remove and replace the controller.

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2026-Engine speed - too high Control Module : CCU Cause: Central control unit ( CCU) has determined engine speed has exceeded preset limits. Possible failure modes: 1. Tractor was in over-speed condition, such as running down hill with load. 2. Central control unit ( CCU) fault Solution: 1. Confirm with the operator that the over-speed condition occurred. A. Operator confirms the over-speed event. Instruct the operator to select a lower transmission gear under these conditions to avoid possible serious engine damage. B. The operator does not confirm the over-speed event. Erase all fault codes and return unit to field operation. Continue to monitor for over-speed conditions.

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2037-Clutch pedal switch - open circuit Control Module : CCU Context: Cause: Clutch disconnect switch is open above 30 % of the clutch pedal position as indicated by the potentiometer. Open circuit between the clutch disconnect switch and the central control unit ( CCU), or the switch is faulty. Effects: Transmission disabled. Possible failure modes: 1. Faulty connectors 2. Incorrect clutch disconnect switch adjustment 3. Clutch disconnect switch faulty 4. Wiring fault 5. Central control unit ( CCU) fault Solution: 1. Check the clutch disconnect switch in H7 Channel 1. A. Position the forward/reverse shuttle lever into gear. Operate the clutch pedal from fully depressed to fully released. The display should indicate the switch is closed before 15 %. If the switch is closed after 15 % of pedal travel, adjust the switch as required. If the display does not indicate the switch has closed, continue to step 2 B. If the switch is adjusted correctly, while in H7 Channel 1 wiggle the harness, the disconnect switch connector X-319 and the connectors of the control unit ( CCU) X-200 and X-210 to check for an intermittent circuit. Channel 1 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the clutch disconnect switch connector X-319, shuttle lever assembly connector X-318, and the connectors of the control unit ( CCU) X-200 and X-210. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 3 3. Check the clutch disconnect switch. A. Disconnect the connector X-319. Check between the component side of connector: X-319 pin 2 and X-319 pin 3 should indicate a closed circuit with the pedal released and an open circuit with the pedal depressed. X-319 pin 1 and X-319 pin 4 should indicate an open circuit with the pedal released and a closed circuit with the pedal depressed If the switch is not okay, remove and replace the clutch disconnect switch. B. If the switch is okay, continue to step 4 4. Check for + 12 V. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-319 pin 1, wire 0.5 (BL/YE) and ground If the indicated voltage is not approximately + 12 V, repair or replace the harness as required. B. If approximately + 12 V is indicated continue to step 5 5. Check for an open circuit. A. Turn the ignition key switch to the ‘OFF’ position. Disconnect the connectors X-318 and X-200. Check between: 47538922 29/05/2013

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X-319 pin 4, wire 0.5 (GY) and X-318 pin 12, wire 0.5 (GY) X-319 pin 3, wire 0.5 (WH/BL) and X-318 pin 7, wire 0.5 (WH/BL) X-319 pin 2, wire 0.5 (YE/BK) and X-200 pin 8, wire 0.5 (YE/BK) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit ( CCU).

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Wire harnesses - Electrical schematic frame 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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Electrical systems - FAULT CODES

2038-Clutch 4 solenoid - short to 12V Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled Possible failure modes: 1. Faulty connector 2. Faulty clutch 4 solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the clutch 4 solenoid in H9 Channel 101. A. Start the engine and select 5th gear, the H9 reading should change from 0 - 750 mA. if reading is incorrect, continue to step 2 B. If the values displayed are okay, while in H9 Channel 101, wiggle the harness, the clutch 4 connector X-365, controller connectors X-200 and X-240, and the inline harness connector X-300 to check for an intermittent circuit. Channel 101 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the clutch 4 solenoid connector X-365, the controller connectors X-200 and X-240, and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the clutch 4 solenoid for a short to ground. A. Disconnect connector X-365. Measure the resistance between the component side of connector: X-365 pin 1 and ground X-365 pin 2 and ground If a short to ground is indicated, remove and replace the clutch solenoid. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to ground. A. Disconnect connectors X-200 and X-240. Check between connector: X-365 pin 1 (RD) and ground X-365 pin 2 (BK/WH) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for a short to +12 Volts. A. Turn the keystart ON. Measure the voltage between connector: X-365 pin 1 (RD) and ground X-365 pin 2 (BK/WH) and ground If +12 Volts is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller. 47538922 29/05/2013

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2039-Clutch 4 solenoid - open circuit Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled Possible failure modes: 1. Faulty connector 2. Faulty clutch 4 solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the clutch 4 solenoid in H9 Channel 101. A. Start the engine and select 5th gear, the H9 reading should change from 0 - 750 mA. if reading is incorrect, continue to step 2 B. If the values displayed are okay, while in H9 Channel 101, wiggle the harness, the clutch 4 connector X-365, controller connectors X-200 and X-240, and the inline harness connector X-300 to check for an intermittent circuit. Channel 101 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the clutch 4 solenoid connector X-365 the controller connectors X-200 and X-240 and the inline harness connector X-300. A. Ensure the connectors is connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the clutch 4 solenoid. A. Disconnect connector X-365. Measure the resistance between the component side of connector, X-365 pin 1 and 2. If the resistance indicated is not between 8 Ohms - 12 Ohms at 20 degrees centigrade, remove and replace the clutch solenoid. B. If the clutch 4 solenoid is okay, continue to step 4 4. Check for an open circuit. A. Disconnect connectors X-200 and X-240. Check between connector: X-365 pin 1 (RD) and X-200 pin 11 (RD) X-365 pin 2 (BK/WH) and X-240 pin 3 (BK/WH) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2040-Clutch 3 solenoid - short to 12V Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled Possible failure modes: 1. Faulty connector 2. Faulty clutch 3 solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the clutch 3 solenoid in H9 Channel 100. A. Start the engine and select 6th gear, the H9 reading should change from 0 - 750 mA. If reading is incorrect, continue to step 2 B. If the values displayed are okay, while in H9 Channel 100, wiggle the harness, the clutch 3 connector X-340, controller connectors X-200 and X-240, and the inline harness connector X-300 to check for an intermittent circuit. Channel 100 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the clutch 3 solenoid connector X-340, the controller connectors X-200 and X-240, and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the clutch 3 solenoid for short to ground. A. Disconnect connector X-340. Check between the component side of connector: X-340 pin 1 and ground X-340 pin 2 and ground If a short to ground is indicated, remove and replace the clutch solenoid. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to ground. A. Disconnect connector X-200 and X-240. Check between connector: X-340 pin 1 (RD/GN) and ground X-340 pin 2 (OR/BK) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for a short to +12 Volts. A. Turn the keystart ON. Measure the voltage between connector: X-340 pin 1 (RD/GN) and ground X-340 pin 2 (OR/BK) and ground If +12 Volts is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller. 47538922 29/05/2013

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2041-Clutch 3 solenoid - open circuit Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled Possible failure modes: 1. Faulty connector 2. Faulty clutch 3 solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the clutch 3 solenoid in H9 Channel 100. A. Start the engine and select 6th gear, the H9 reading should change from 0 - 750 mA. If reading is incorrect, continue to step 2 B. If the values displayed are okay, while in H9 Channel 100, wiggle the harness, the clutch 3 connector X-340, controller connectors X-200 and X-240, and the inline harness connector X-300 to check for an intermittent circuit. Channel 100 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the clutch 3 solenoid connector X-340, the controller connectors X-200 and X-240 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the clutch 3 solenoid. A. Disconnect connector X-340. Measure the resistance between the component side of connector, X-340 pin 1 and 2. If the resistance indicated is not between 8 Ohms - 12 Ohms at 20 degrees centigrade, remove and replace the clutch 3 solenoid. B. If the clutch 3 solenoid is okay, continue to step 4 4. Check for an open circuit. A. Disconnect connectors X-200 and X-240. Check between connector: X-340 pin 1 (RD/GN) and X-200 pin 4 (RD/GN) X-340 pin 2 (OR/BK) and X-240 pin 2 (OR/BK) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2042-Clutch 2 solenoid - short to 12V Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled Possible failure modes: 1. Faulty connector 2. Faulty clutch 2 solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the clutch 2 solenoid in H9 Channel 103. A. Start the engine and select 2nd gear, the H9 reading should change from 0 - 750 mA. If reading is incorrect, continue to step 2 B. If the values displayed are okay, while in H9 Channel 103, wiggle the harness, the clutch 2 connector X-807, controller connector X-200, X-240 and the inline harness connector X-300 to check for an intermittent circuit. Channel 103 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the clutch 2 solenoid connector X-807, the controller connectors X-200, X-240 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the clutch 2 solenoid for short to ground. A. Disconnect connector X-807. Check between the component side of connector: X-807 pin 1 and ground. X-807 pin 2 and ground. If a short to ground is indicated, remove and replace the clutch solenoid. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to ground. A. Disconnect connectors X-200 and X-240. Check between connector: X-807 pin 1 (GN/WH) and ground X-807 pin 2 (GN/BK) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for a short to +12 Volts. A. Turn the keystart ON. Measure the voltage between connector: X-807 pin 1 (GN/WH) and ground X-807 pin 2 (GN/BK) and ground If +12 Volts is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller. 47538922 29/05/2013

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2043-Clutch 2 solenoid - open circuit Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled Possible failure modes: 1. Faulty connector 2. Faulty clutch 2 solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the clutch 2 solenoid in H9 Channel 103. A. Start the engine and select 2nd gear, the H9 reading should change from 0 - 750 mA. If reading is incorrect, continue to step 2 B. If the values displayed are okay, while in H9 Channel 103, wiggle the harness, the clutch 2 connector X-807, controller connectors X-200, X-240 and the inline harness connector X-300 to check for an intermittent circuit. Channel 103 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the clutch 2 solenoid connector X-807 the controller connectors X-200, X-240 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the clutch 2 solenoid. A. Disconnect connector X-807. Measure the resistance between the component side of connector, X-807 pin 1 and 2. If the resistance indicated is not between 8 Ohms - 12 Ohms at 20 degrees centigrade, remove and replace the clutch solenoid. B. If the clutch 2 solenoid is okay, continue to step 4 4. Check for an open circuit. A. Disconnect connectors X-200 and X-240. Check between connector: X-807 pin 1 (GN/WH) and X-200 pin 7 (GN/WH) X-807 pin 2 (GN/BK) and X-240 pin 4 (GN/BK) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2044-Clutch 1 solenoid - short to 12V Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled Possible failure modes: 1. Faulty connector 2. Faulty clutch 1 solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the clutch 1 solenoid in H9 Channel 102. A. Start the engine and select 3rd gear, the H9 reading should change from 0 - 750 mA. If reading is incorrect, continue to step 2 B. If the values displayed are okay, while in H9 Channel 102, wiggle the harness, the clutch 1 connector X-806, controller connectors X-200 and X-240 and the inline harness connector X-300 to check for an intermittent circuit. Channel 102 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the clutch 1 solenoid connector X-806 the controller connectors X-200 and X-240 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the clutch 1 solenoid for short to ground. A. Disconnect connector X-806. Check between the component side of connector: X-806 pin 1 and ground X-806 pin 2 and ground If a short to ground is indicated, remove and replace the clutch solenoid. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to ground. A. Disconnect connector X-200 and X-240. Check between connector: X-806 pin 1 (VT) and ground X-806 pin 2 (BK/YE) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for short to +12 Volts. A. Turn the keystart ON. Measure the voltage between connector: X-806 pin 1 (VT) and ground X-806 pin 2 (BK/YE) and ground. If +12 Volts is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller. 47538922 29/05/2013

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2045-Clutch 1 solenoid - open circuit Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled Cause: Possible failure modes: 1. Faulty connector 2. Faulty clutch 1 solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the clutch 1 solenoid in H9 Channel 102. A. Start the engine and select 3rd gear, the H9 reading should change from 0 - 750 mA. If reading is incorrect, continue to step 2 B. If the values displayed are okay, while in H9 Channel 102, wiggle the harness, the clutch 1 connector X-806, controller connectors X-200 and X-240 and the inline harness connector X-300 to check for an intermittent circuit. Channel 102 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the clutch 1 solenoid connector X-806 the controller connectors X-200 and X-240 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the clutch 1 solenoid. A. Disconnect connector X-806. Measure the resistance between the component side of connector. X-806 pin 1 and 2. If the resistance indicated is not between 8 Ohms - 12 Ohms at 20 degrees centigrade, remove and replace the clutch solenoid. B. If the clutch 1 solenoid is okay, continue to step 4 4. Check for an open circuit. A. Disconnect connectors X-200 and X-240. Check between connector: X-806 pin 1 (VT) and X-200 pin 6 (VT) X-806 pin 2 (BK/YE) and X-240 pin 3 (BK/YE) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2047-Clutch pedal switch set too high Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Incorrect clutch pedal disconnect switch adjustment Solution: 1. Check the clutch pedal disconnect switch adjustment in H7 Channel 1. A. While in H7 Channel 1, check the clutch pedal disconnect switch operates between open and closed. Place the shuttle lever in forward. When the display shows ‘CP’, depress the clutch pedal. When the clutch pedal is released, while in H7 Channel 1 the display will indicate a value in the range of 8 to 14 if the switch is correctly adjusted. If the switch is incorrectly adjusted the display will indicate ‘CL’ if the clutch pedal switch adjustment bolt needs to be rotated clockwise, or ‘CCL’ if the clutch pedal switch adjustment bolt needs to be rotated counterclockwise. Adjust the clutch pedal disconnect switch adjustment bolt as required.

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2048-Clutch pedal switch set too low Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Incorrect clutch pedal disconnect switch adjustment Solution: 1. Check the clutch pedal disconnect switch adjustment in H7 Channel 1. A. While in H7 Channel 1, check the clutch pedal disconnect switch operates between open and closed. Place the shuttle lever in forward. When the display shows ‘CP’, depress the clutch pedal. When the clutch pedal is released, while in H7 Channel 1 the display will indicate a value in the range of 8 to 14 if the switch is correctly adjusted. If the switch is incorrectly adjusted the display will indicate ‘CL’ if the clutch pedal switch adjustment bolt needs to be rotated clockwise, or ‘CCL’ if the clutch pedal switch adjustment bolt needs to be rotated counterclockwise. Adjust the clutch pedal disconnect switch adjustment bolt as required.

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2049-Wheel speed sensor - short to ground or open circuit Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty wheel speed sensor 3. Faulty harness 4. Faulty controller Solution: 1. Check the wheel speed sensor connector X-309, the controller connector X-240 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check for 12 Volts. A. Disconnect connector X-309. Turn the ignition key switch ON. Measure the voltage between connector X-309 pin 2 (WH) and ground. If approximately 12 Volts is not indicated, repair or replace the harness as required. B. If approximately 12 Volts is indicated, continue to step 3 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connector X-240. Check between connector X-240 pin 20 (OR/ BL) and X-309 pin 1 (OR/BL). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 4 4. Check for a short to ground. A. Check between connector X-240 pin 20 (OR/BL) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the output wheel speed sensor. If the fault is still present, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2050-Transmission output speed sensor - signal too high Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty wheel speed sensor 3. Faulty harness 4. Faulty controller Solution: 1. Check the wheel speed sensor connector X-309, the controller connector X-240 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check for 12 Volts. A. Disconnect connector X-309. Turn the ignition key switch ON. Measure the voltage between connector X-309 pin 2 (WH) and ground. If approximately 12 Volts is not indicated, repair or replace the harness as required. B. If approximately 12 Volts is indicated, continue to step 3 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connector X-240. Check between connector X-240 pin 20 (OR/ BL) and X-309 pin 1 (OR/BL). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 4 4. Check for a short to +Ve voltage. A. Turn the ignition key switch ON. Measure the voltage between connector X-309 pin 1 (OR/BL) and ground. If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 5 5. Check for a short circuit. A. Check between connector X-309 pin 1 (OR/BL) and X-309 pin 2 (WH). If a short circuit is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the wheel speed sensor. If the fault is still present, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2051-Transmission oil temperature sensor - signal too high Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Hot oil is assumed. If the oil is cold, sluggish shifting and a higher than normal clutch pedal bite point will be indicated. Cause: Open circuit or short to power on the transmission oil temperature sense line. Possible failure modes: 1. Faulty connector 2. Faulty oil temperature sensor 3. Faulty harness 4. Faulty controller Solution: 1. Check the transmission oil temperature sensor in H9 Channel 14. A. The value will change dependant on temperature between 340 - 4510 mV is displayed, if reading is incorrect, continue to step 2 B. If the values displayed are okay, while in H9 Channel 14 wiggle the harness, the transmission oil temperature sensor connector X-316, the controller connector X-210 and the inline harness connector X-300 to check for an intermittent circuit. Channel 14 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the temperature sensor connector X-316, controller connector X-210 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the temperature sensor. A. Disconnect connector X-316. Measure the resistance between the component side of connector X-316 pins A and B. If the resistance indicated is not between 460 Ohms - 540 Ohms at 25 degrees centigrade, remove and replace the temperature sensor. B. If the temperature sensor is okay, continue to step 4 4. Check for an open circuit. A. Disconnect connector X-210. Check between connector: X-316 pin B (BL/RD) and X-210 pin 14 (BL/RD) X-316 pin A (BK/WH) and ground If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated continue to step 5 5. Check for a short to Ve voltage. A. Turn the ignition key ON. Measure the voltage between connector X-210 pin 14 (BL/RD) and ground. If a voltage is indicated, repair or replace the harness as required.

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B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2052-Transmission oil temperature sensor - signal too low Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Hot oil is assumed. If the oil is cold, sluggish shifting and a higher than normal clutch pedal bite point will be indicated Cause: Short to ground on the transmission oil temperature sense line. Possible failure modes: 1. Faulty connector 2. Faulty oil temperature sensor 3. Faulty harness 4. Faulty controller Solution: 1. Check the transmission oil temperature sensor in H9 Channel 14. A. The value will change dependant on temperature between 340 - 4510 mV is displayed, if reading is incorrect, continue to step 2 B. If the values displayed are okay, while in H9 Channel 14 wiggle the harness, the transmission oil temperature sensor connector X-316, the controller connector X-210 and the inline harness connector X-300 to check for an intermittent circuit. Channel 2 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the temperature sensor connector X-316, the controller connector X-210 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the temperature sensor for a short to ground. A. Disconnect connector X-316. Check between the component side of connector: X-316 pin A and ground X-316 pin B and ground If short to ground is indicated, remove and replace the temperature sensor. B. If the temperature sensor is okay, continue to step 4 4. Check for a short to ground. A. Disconnect connector X-210. Check between connector X-316 pin B (BL/RD) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2053-5V reference voltage - voltage too high Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled. Cause: Short to power detected at the controller connector X-210 pin 17 (5V ref). Possible failure modes: 1. Faulty shuttle lever switch 2. Faulty clutch pedal potentiometer 3. Faulty harness 4. Faulty controller Solution: 1. Check for other transmission related error codes being displayed. A. If any other transmission related error codes are being displayed, continue to these tests. B. If no other transmission related error code is displayed, continue to step 2 2. Check for a short to +Ve voltage. A. Disconnect the controller connector X-210. Measure the voltage between connector X-210 pin 17 (TQ/WH) and ground. If a voltage is indicated, disconnect the shuttle lever connector X-318, the clutch pedal potentiometer connector X-322 and any other transmission components which are connected to connector X-210 pin 17 (TQ/ WH) (5V ref) one at a time and check if a voltage is still present. If a voltage is not present after disconnecting the component, remove and replace the faulty component. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

03 04 14 15

(55.100.DP-C.20.E.03) (55.100.DP-C.20.E.04) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15)

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2054-5V reference voltage - voltage too low Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled. Cause: Short to ground detected at the controller connector X-210 pin 17 (5V ref). Possible failure modes: 1. Faulty shuttle lever switch 2. Faulty clutch pedal potentiometer 3. Faulty harness 4. Faulty controller Solution: 1. Check for other transmission related error codes being displayed. A. If any other transmission related error codes are being displayed, continue to these tests. B. If no other transmission related error code is displayed, continue to step 2 2. Check for a short to ground. A. Disconnect the controller connector X-210. Check between connector X-210 pin 17 (TQ/WH) and ground. If a short to ground is indicated, disconnect the shuttle lever connector X-318, the clutch pedal potentiometer connector X-322 and any other transmission components which are connected to connector X-210 pin 17 (TQ/ WH) (5V ref) one at a time and check if a short to ground is still present. If a short to ground is not present after disconnecting the component, remove and replace the faulty component. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

03 04 14 15

(55.100.DP-C.20.E.03) (55.100.DP-C.20.E.04) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15)

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2055-Transmission output speed sensor - implausible speed drop detected Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: No signal comes from the sensor but short to 12 V or short to ground faults are not present. Possible failure modes: 1. Faulty connector 2. Faulty wheel speed sensor 3. Faulty harness 4. Mechanical fault within the transmission Solution: 1. Check for other error codes being displayed. A. If any other error code is being displayed, continue to these tests. B. If no other error code is displayed, continue to step 2 2. Check the wheel speed sensor connector X-309, the controller connector X-240 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for 12 Volts. A. Disconnect connector X-309. Turn the ignition key switch ON. Measure the voltage between connector X-309 pin 2 (WH) and ground. If approximately 12 Volts is not indicated, repair or replace the harness as required. B. If approximately 12 Volts is indicated, continue to step 3 4. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connector X-240. Check between connector X-240 pin 20 (OR/ BL) and X-309 pin 1 (OR/BL). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 4 5. Check the output wheel speed sensor. A. If installed incorrectly, loose or damaged, refit correctly or replace as required. B. If the sensor is installed correctly, remove and replace the wheel speed sensor. If fault is still present, possible fault with the speed sensor inductive ring.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2056-Low Range switch open circuit Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty switch 3. Faulty harness 4. Faulty controller Solution: 1. Check low range switch connector X-199, controller connector X-230 and harness connector X-300. A. Check whether the connectors are plugged in, there is no damage, the pins are in the right positions and the connectors are secure. Repair or replace as necessary. B. If the connector is okay, continue to step 2 2. Check for + 5 Volts. A. Disconnect connector X-199. Turn the ignition key switch ON. Measure the voltage between connector X-199 pin B (TQ/WH) and ground. If + 5 Volts is not indicated, repair or replace the harness as required to connector X-210 pin 17 (TQ/WH). B. If + 5 Volts is indicated, continue to step 3 3. Check switch operation. A. Remove the switch and check operation of switch using a multimeter. Repair or replace the switch if necessary. B. If the switch is okay, continue to 4 4. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connector X-230. Check between connector X-199 pin A (OR) and X-230 pin 5 (OR). If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2057-High Range switch open circuit Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty switch 3. Faulty harness 4. Faulty controller Solution: 1. Check high range switch connector X-308, controller connector X-230 and harness connector X-300. A. Check whether the connectors are plugged in, there is no damage, the pins are in the right positions and the connectors are secure. Repair or replace as necessary. B. If the connector is okay, continue to step 2 2. Check for + 5 Volts. A. Disconnect connector X-308. Turn the ignition key ON. Measure the voltage between connector X-308 pin B (TQ/WH) and ground. If + 5 Volts is not indicated, repair or replace the harness as required. B. If + 5 Volts is indicated, continue to step 3 3. Check switch operation. A. Remove the switch and check operation of switch using a multimeter. Repair or replace the switch if necessary. B. If the switch is okay, continue to 4 4. Check for an open circuit. A. Disconnect connector X-230. Check between connector X-308 pin A (GY/RD) and X-230 pin 18 (GY/RD) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2059-Shuttle lever - implausible signals Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission is disabled. Possible failure modes: 1. Faulty shuttle lever switch 2. Faulty harness 3. Fault controller Solution: 1. Check the shuttle lever switch. A. Disconnect the shuttle lever switch connector X-318. With the shuttle lever in neutral, measure the resistance between the component side of connector: X-318 pin 1 (TQ/WH) and X-318 pin 2 (WH/GN) should indicate approximately 2.7K Ohms X-318 pin 1 (TQ/WH) and X-318 pin 3 (YE/GN) should indicate approximately 2.7K Ohms If the resistances indicated are not okay, remove and replace the shuttle lever switch. B. If the shuttle lever switch is okay, continue to step 2 2. Check for a short circuit. A. Check between connector X-318 pin 2 (WH/GN) and X-318 pin 3 (YE/GN). If a short circuit is indicated, repair or replace the harness as required. B. If a short circuit is not indicated, continue to step 3 3. Check for a short to Ve voltage. A. Turn the ignition key switch ON. Measure between connector. X-318 pin 2 (WH/GN) and ground X-318 pin 3 (YE/GN) and ground If a voltage is indicated, repair or replace the harness as required B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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2061-Forward/reverse synchroniser potentiometer signal too high Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty forward/reverse synchroniser potentiometer 3. Faulty harness 4. Faulty controller Solution: 1. Check the forward/reverse synchroniser potentiometer connector X-195, the controller connector X-210 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight, repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the forward/reverse synchroniser potentiometer. A. Disconnect the connector X-195 and remove the potentiometer. While rotating the potentiometer between the maximum and minimum positions, measure the resistance between the component side of connector: X-195 pin 2 and X-195 pin 3 should indicate between approximately 1.00 K Ohms and 5.0 K Ohms X-195 pin 2 and X-195 pin 1 should indicate between approximately 5.0 K Ohms and 1.00 K Ohms If the resistances indicated are not okay, remove and replace the potentiometer. B. If the potentiometer is okay, continue to step 3 3. Check for 5 Volts. A. Turn the ignition key switch ON. Measure the voltage between connector X-195 pin 1 (TQ/WH) and ground. If approximately 5 Volts is not indicated, repair or replace the harness as required. B. If approximately 5 Volts is indicated, continue to step 4 4. Check for an open ground circuit. A. Check between connector X-195 pin 3 (BK/WH) and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connector X-195. Check between connector X-210 pin 1 (GY/GN) and X-195 pin 2 (GY/GN). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 6 6. Check for a short circuit. A. Check between connector X-195 pin 2 (GY/GN) and X-195 pin 1 (TQ/WH). If a short circuit is indicated, repair or replace the harness as required. B. If a short circuit is not indicated, continue to step 7 7. Check for a short to Ve voltage.

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A. Turn the ignition key switch ON. Measure the voltage between connector X-195 pin 2 (GY/GN) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2062-Forward/reverse synchroniser potentiometer signal too low Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty forward/reverse synchroniser potentiometer 3. Faulty harness 4. Faulty controller Solution: 1. Check the forward/reverse synchroniser potentiometer connector X-195, the controller connector X-210 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight, repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the forward/reverse synchroniser potentiometer. A. Disconnect the connector X-195 and remove the potentiometer. While rotating the potentiometer between the maximum and minimum positions, measure the resistance between the component side of connector: X-195 pin 2 and X-195 pin 3 should indicate between approximately 1.00 K Ohms and 5.0 K Ohms X-195 pin 2 and X-195 pin 1 should indicate between approximately 5.0 K Ohms and 1.00 K Ohms If the resistances indicated are not okay, remove and replace the potentiometer. B. If the potentiometer is okay, continue to step 3 3. Check for 5 Volts. A. Turn the ignition key switch ON. Measure the voltage between connector X-195 pin 1 (TQ/WH) and ground. If approximately 5 Volts is not indicated, repair or replace the harness as required. B. If approximately 5 Volts is indicated, continue to step 4 4. Check for an open ground circuit. A. Check between connector X-195 pin 3 (BK/WH) and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connector X-210. Check between connector X-210 pin 1 (GY/GN) and X-195 pin 2 (GY/GN). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 6 6. Check for a short circuit. A. Check between connector X-195 pin 2 (GY/GN) and X-195 pin 3 (BK/WH). If a short circuit is indicated, repair or replace the harness as required. B. If a short circuit is not indicated, continue to step 7 7. Check for a short to ground.

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A. Check between connector X-195 pin 2 (GY/GN) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2063-Forward synchroniser did not engage Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty forward synchroniser solenoid 2. Faulty forward/reverse potentiometer 3. Faulty hydraulic circuit 4. Mechanical fault Solution: 1. Check for other error codes being displayed. A. If any other error codes are being displayed, continue to these tests. B. If no other error codes are displayed, continue to step 2 2. Clear the error code and test the system for normal operation. A. If the error code re-occurs, continue to step 3 3. Check the forward solenoid. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, continue to step 4 4. Check the hydraulic pressures. A. If the pressures indicated are okay, possible mechanical fault within the transmission. If the pressure is low, continue to hydraulic troubleshooting procedures. B. If the pressure is correct investigate the mechanical operation.

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2064-Reverse synchroniser did not engage Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty reverse synchroniser solenoid 2. Faulty forward/reverse potentiometer 3. Faulty hydraulic circuit 4. Mechanical fault Solution: 1. Check for other error codes being displayed. A. If any other error codes are being displayed, continue to these tests. B. If no other error codes are displayed, continue to step 2 2. Clear the error code and test the system for normal operation. A. If the error code re-occurs, continue to step 3 3. Check the reverse solenoid. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, continue to step 4 4. Check the hydraulic pressures. A. If the pressures indicated are okay, possible mechanical fault within the transmission. If the pressure is low, continue to hydraulic troubleshooting procedures. B. If the pressure is correct investigate the mechanical operation.

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2065-Forward synchroniser solenoid - open circuit Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Failure to engage reverse gear Possible failure modes: 1. Faulty connector 2. Faulty forward synchroniser solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the forward synchroniser solenoid connector X-184, the controller connector X-240 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the forward synchroniser solenoid. A. Disconnect connector X-184. Check between the component side of connector. X-184 pin 1 and 2. If the resistance indicated is not between 8 Ohms - 12 Ohms at 20 degrees centigrade, remove and replace the forward gear solenoid. B. If the forward synchroniser solenoid is okay, continue to step 3 3. Check for an open circuit. A. Disconnect connector X-240. Check between connector: X-184 pin 1 (WH) and X-240 pin 5 (WH) X-184 pin 2 (WH/BK) and X-240 pin 10 (WH/BK) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2066-Reverse synchroniser solenoid - open circuit Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Failure to engage reverse gear Possible failure modes: 1. Faulty connector 2. Faulty reverse synchroniser solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the reverse synchroniser solenoid connector X-185 the controller connectors X-240 and X-220 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the reverse synchroniser solenoid. A. Disconnect connector X-185. Check between the component side of connector. X-185 pin 1 and 2. If the resistance indicated is not between 8 Ohms - 12 Ohms at 20 degrees centigrade, replace the reverse synchroniser solenoid. B. If the reverse synchroniser solenoid is okay, continue to step 3 3. Check for an open circuit. A. Disconnect connectors X-240 and X-220. Check between connector: X-185 pin 1 (WH/GN) and X-240 pin 7 (WH/GN) X-185 pin 2 (WH/TQ) and X-220 pin 2 (WH/TQ) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, replace and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2067-Forward synchroniser solenoid - short to 12V Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled Possible failure modes: 1. Faulty connector 2. Faulty forward synchroniser solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the forward synchroniser solenoid connector X-184 the controller connector X-240 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the forward synchroniser solenoid for short to ground. A. Disconnect connector X-184. Check between the component side of connector: X-184 pin 1 and ground X-184 pin 2 and ground If a short to ground is indicated, remove and replace the forward synchroniser solenoid. B. If a short to ground is not indicated, continue to step 3 3. Check for a short to ground. A. Disconnect connector X-240. Check between connector: X-184 pin 1 (WH) and ground X-184 pin 2 (WH/BK) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the a short to ground is not indicated, continue to step 4 4. Check for a short to +Ve Voltage. A. Turn the ignition key switch ON. Measure the voltage between connector: X-184 pin 1 (WH) and ground X-184 pin 2 (WH/BK) and ground If a short to +Ve voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2068-Reverse synchroniser solenoid - short to 12V Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled Possible failure modes: 1. Faulty connector 2. Faulty reverse synchroniser solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the reverse synchroniser solenoid connector X-185 the controller connectors X-240 and X-220 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the reverse synchroniser solenoid for short to ground. A. Disconnect connector X-185. Check between the component side of connector: X-185 pin 1 and ground X-185 pin 2 and ground If a short to ground is indicated, replace the reverse synchoniser solenoid. B. If a short to ground is not indicated, continue to step 3 3. Check for a short to ground. A. Disconnect connectors X-240 and X-220. Check between connector: X-185 pin 1 (WH/GN) and ground X-185 pin 2 (WH/TQ) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to +Ve voltage. A. Turn the ignition key switch ON. Measure the voltage between connector: X-185 pin 1 (WH/GN) and ground X-185 pin 2 (WH/TQ) and ground If a short to +Ve voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2070-Shuttle lever forward switch - voltage too high Control Module : CCU Context: Cause: Short to a positive voltage between the shuttle lever forward switch and the central control unit ( CCU), or the shuttle lever assembly is faulty. Effects: There will be a short delay recognising that forward has been selected. Possible failure modes: 1. Faulty connectors 2. Faulty shuttle lever assembly 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the shuttle lever forward switch in H5. A. Turn the ignition key switch ’ON’. Move the shuttle lever into forward. If the display does not change to d15, continue to step 2 B. If the display does change to d15, while still in H5 wiggle the harness and the connectors to check for an intermittent circuit. The display will change if an intermittent circuit is detected: Repair or replace as necessary. 2. Check the shuttle lever forward switch. A. Disconnect the shuttle lever connector X-318. Move the shuttle lever forward and measure the resistance between the component side of connector: X-318 between pin 1 and X-318 pin 2 If the resistance indicated is not approximately 560 Ω, and with the shuttle lever released approximately 2760 Ω, remove and replace the shuttle lever assembly. B. If the shuttle lever switch is okay, continue to step 3 3. Check for a short to + 8 V or + 12 V. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-318 pin 1, wire 0.5 (TQ/WH) and ground If the indicated voltage is greater than + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 4 4. Check for a short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-318 pin 2, wire 0.5 (WH/GN) and ground If voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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2071-Shuttle lever forward switch - voltage too low Control Module : CCU Context: Cause: Open circuit or short to ground between the switch of the forward gear, of the shuttle lever and the central control unit ( CCU), or the shuttle lever assembly is faulty. Effects: There will be a short delay recognising that forward has been selected. Possible failure modes: 1. Faulty connectors 2. Faulty shuttle lever assembly 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the shuttle lever forward switch in H5. A. Turn the ignition key switch ’ON’. Move the shuttle lever into forward. If the display does not change to d15, continue to step 2 B. If the display does change to d15, while still in H5 wiggle the harness and the connectors to check for an intermittent circuit. The display will change if an intermittent circuit is detected: Repair or replace as necessary. 2. Check the shuttle lever forward switch. A. Disconnect the shuttle lever connector X-318. Move the shuttle lever forward and measure the resistance between the component side of connector: X-318 between pin 1 and X-318 pin 2 If the resistance indicated is not approximately 560 Ω, and with the shuttle lever released approximately 2760 Ω, remove and replace the shuttle lever assembly. B. If the shuttle lever switch is okay, continue to step 3 3. Check for + 5 V. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-318 pin 1, wire 0.5 (TQ/WH) and ground If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 4 4. Check for an open circuit. A. Turn ignition switch to OFF position. Disconnect the connector of the central control unit ( CCU) X-210. Check in the connector: X-210 between pin 12, wire 0.5 (WH/GN) and X-318 pin 2, wire 0.5 (WH/GN) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue with step 5 5. Check for a short to ground. A. Check between the connector: X-210 between pin 12, wire 0.5 (WH/GN) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU). 47538922 29/05/2013

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Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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2072-Shuttle lever reverse switch - voltage too high Control Module : CCU Context: Cause: Short to a positive voltage between the shuttle lever reverse switch and the central control unit ( CCU), or the shuttle lever assembly is faulty. Effects: There will be a short delay recognising that reverse has been selected. Possible failure modes: 1. Faulty connectors 2. Faulty shuttle lever assembly 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the shuttle lever reverse switch in H5. A. Turn the ignition key switch ’ON’. Move the shuttle lever into reverse. If the display does not change to d16, continue to step 2 B. If the display does change to d16, while still in H5 wiggle the harness and the connectors to check for an intermittent circuit. The display will change if an intermittent circuit is detected: Repair or replace as necessary. 2. Check the shuttle lever reverse switch. A. Disconnect the shuttle lever connector X-318. Move the shuttle lever to reverse and measure the resistance between the component side of connector: X-318 pin 1, and X-318 pin 3 If the resistance indicated is not approximately 560 Ω, and with the shuttle lever released approximately 2760 Ω, remove and replace the shuttle lever assembly. B. If the shuttle lever switch is okay, continue to step 3 3. Check for a short to + 8 V or + 12 V. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-318 pin 1, wire 0.5 (TQ/WH) and ground If the indicated voltage is greater than + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 4 4. Check for short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-318 pin 3, wire 0.5 (YE/GN) and ground If voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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2073-Shuttle lever reverse switch - voltage too low Control Module : CCU Context: Cause: Open circuit or short to ground between the switch of the reverse gear, of the shuttle lever and the central control unit ( CCU), or the shuttle lever assembly is faulty. Effects: There will be a short delay recognising that reverse has been selected. Possible failure modes: 1. Faulty connectors 2. Faulty shuttle lever assembly 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the shuttle lever reverse switch in H5. A. Turn the ignition key switch ’ON’. Move the shuttle lever into reverse. If the display does not change to d16, continue to step 2 B. If the display does change to d16, while still in H5 wiggle the harness and the connectors to check for an intermittent circuit. The display will change if an intermittent circuit is detected: Repair or replace as necessary. 2. Check the shuttle lever reverse switch. A. Disconnect the shuttle lever connector X-318. Move the shuttle lever to reverse and measure the resistance between the component side of connector: X-318 pin 1, and X-318 pin 3 If the resistance indicated is not approximately 560 Ω, and with the shuttle lever released approximately 2760 Ω, remove and replace the shuttle lever assembly. B. If the shuttle lever switch is okay, continue to step 3 3. Check for + 5 V. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-318 pin 1, wire 0.5 (TQ/WH) and ground If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. B. If the voltage indicated is approximately + 5 V, continue to step 4 4. Check for an open circuit. A. Turn ignition switch to OFF position. Disconnect the connector of the central control unit ( CCU) X-210. Check in the connector: X-210 between pin 13, wire 0.5 (YE/GN) and X-318 pin 3, wire 0.5 (YE/GN) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue with step 5 5. Check for a short to ground. A. Check between the connector: X-210 between pin 13, wire 0.5 (YE/GN) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU). 47538922 29/05/2013

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Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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2081-4/5 range synchroniser potentiometer - signal high Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty 4/5 synchroniser potentiometer 3. Faulty harness 4. Faulty controller Solution: 1. Check the 4/5 synchroniser potentiometer connector X-194, the controller connector X-230 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight, repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the 4/5 synchroniser potentiometer. A. Disconnect the connector X-194 and remove the potentiometer. While rotating the potentiometer between the maximum and minimum positions, measure the resistance between the component side of connector: X-194 pin 2 and X-194 pin 3 should indicate between approximately 1.00 K Ohms and 5.0 K Ohms X-194 pin 2 and X-194 pin 1 should indicate between approximately 5.0 K Ohms and 1.00 K Ohms If the resistances indicated are not okay, remove and replace the potentiometer. B. If the potentiometer is okay, continue to step 3 3. Check for 5 Volts. A. Turn the ignition key switch ON. Measure the voltage between connector X-194 pin 1 (TQ/WH) and ground. If approximately 5 Volts is not indicated, repair or replace the harness as required. B. If approximately 5 Volts is indicated, continue to step 4 4. Check for an open ground circuit. A. Check between connector X-194 pin 3 (BK/WH) and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connector X-230. Check between connector X-230 pin 2 (GY) and X-194 pin 2 (GY). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 6 6. Check for a short circuit. A. Check between connector X-194 pin 2 (GY) and X-194 pin 1 (TQ/WH). If a short circuit is indicated, repair or replace the harness as required. B. If a short circuit is not indicated, continue to step 7 7. Check for a short to Ve voltage.

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A. Turn the ignition key switch ON. Measure the voltage between connector X-194 pin 2 (GY) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2082-4/5 range synchroniser potentiometer - signal low Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty 4/5 synchroniser potentiometer 3. Faulty harness 4. Faulty controller Solution: 1. Check the 4/5 synchroniser potentiometer connector X-194, the controller connector X-230 and the inline harness connector X-300. A. Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight. repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the 4/5 reverse synchroniser potentiometer. A. Disconnect the connector X-194 and remove the potentiometer. While rotating the potentiometer between the maximum and minimum positions, measure the resistance between the component side of connector: X-194 pin 2 and X-194 pin 3 should indicate between approximately 1.00 K Ohms and 5.0 K Ohms X-194 pin 2 and X-194 pin 1 should indicate between approximately 5.0 K Ohms and 1.00 K Ohms If the resistances indicated are not okay, remove and replace the potentiometer. B. If the potentiometer is okay, continue to step 3 3. Check for 5 Volts. A. Turn the ignition key start ON. Measure the voltage between connector X-194 pin 1 (TQ/WH) and ground. If approximately 5 Volts is not indicated, repair or replace the harness as required. B. If approximately 5 Volts is indicated, continue to step 4 4. Check for an open ground circuit. A. Check between connector X-194 pin 3 (BK/WH) and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Turn the keystart OFF. Disconnect connector X-230. Check between connector X-230 pin 3 (BK/WH) and X-194 pin 2 (GY). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 6 6. Check for a short circuit. A. Check between connector X-194 pin 2 (GY) and X-194 pin 3 (BK/WH). If a short circuit is indicated, repair or replace the harness as required. B. If a short circuit is not indicated, continue to step 7 7. Check for a short to ground.

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A. Check between connector X-194 pin 2 (GY) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2083-1-4 range synchroniser engaged error Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty 1-4 synchroniser solenoid 2. Faulty 4/5 synchroniser potentiometer 3. Faulty hydraulic circuit 4. Mechanical fault Solution: 1. Check for other error codes being displayed. A. If any other error codes are being displayed, continue to these tests. B. If no other error codes are displayed, continue to step 2 2. Clear the error code and test the system for normal operation. A. If the error code re-occurs, continue to step 3 3. Check the 1-4 synchroniser solenoid. X-186 A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, continue to step 4 4. Check the hydraulic pressures. A. If the pressures indicated are okay, possible mechanical fault within the transmission. If the pressure is low, continue to hydraulic troubleshooting procedures. B. If the pressure is correct investigate the mechanical operation.

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Electrical systems - FAULT CODES

2084-5-8 range synchroniser engaged error Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty 5-8 synchroniser solenoid 2. Faulty 4/5 synchroniser potentiometer 3. Faulty hydraulic circuit 4. Mechanical fault Solution: 1. Check for other error codes being displayed. A. If any other error codes are being displayed, continue to these tests. B. If no other error codes are displayed, continue to step 2 2. Clear the error code and test the system for normal operation. A. If the error code re-occurs, continue to step 3 3. Check the 5-8 synchroniser solenoid. X-187 A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, continue to step 4 4. Check the hydraulic pressures. A. If the pressures indicated okay, possible mechanical fault within the transmission. If the pressure is low, continue to hydraulic troubleshooting procedures. B. If the pressure is correct investigate the mechanical operation.

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2085-1-4 range synchroniser solenoid - open circuit Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty 1-4 synchroniser solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the 1-4 synchroniser solenoid connector X-186 the controller connectors X-240 and X-220, and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the 1-4 synchroniser solenoid. A. Disconnect connector X-186. Measure the resistance between the component side of connector X-186 pin 1 and 2. If the resistance indicated is not between 8 Ohms - 12 Ohms at 20 degrees centigrade, remove and replace the 1-4 synchroniser solenoid. B. If the 1-4 synchroniser solenoid is okay, continue to step 3 3. Check for an open circuit. A. Disconnect connector X-240 and X-220. Check between connector: X-186 pin 1 (WH/OR) and X-240 pin 15 (WH/OR) X-186 pin 2 (WH/RD) and X-220 pin 6 (WH/RD) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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2086-5-8 range synchroniser solenoid - open circuit Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty 5-8 synchroniser solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the 5-8 synchroniser solenoid connector X-187, the controller connectors X-240 and X-220, and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connector is okay, continue to step 2 2. Check the 5-8 synchroniser solenoid. A. Disconnect connector X-187. Measure the resistance between the component side of connector X-187 pin 1 and 2. If the resistance indicated is not between 8 Ohms - 12 Ohms at 20 degrees centigrade, replace the 5-8 synchroniser solenoid. B. If the 5-8 synchroniser solenoid is okay, continue to step 3 3. Check for an open circuit. A. Disconnect connectors X-240 and X-220. Check between connector: X-187 pin 1 (WH/BL) and X-240 pin 13 (WH/BL) X-187 pin 2 (WH/YE) and X-220 pin 1 (WH/YE) If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2087-1-4 range synchroniser solenoid - short to 12V Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled Possible failure modes: 1. Faulty connectors 2. Faulty 1-4 synchroniser solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the 1-4 synchroniser solenoid connector X-186, the controller connectors X-240 and X-220 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connector is okay, continue to step 2 2. Check the 1-4 synchroniser solenoid for a short to ground. A. Disconnect connector X-186. Check between the component side of connector: X-186 pin 1 and ground X-186 pin 2 and ground If a short to ground is indicated, replace the 1-4 synchroniser solenoid. B. If a short to ground is not indicated, continue to step 3 3. Check for a short to ground. A. Disconnect connector X-240 and X-220. Check between connector: X-186 pin 1 (WH/OR) and ground X-186 pin 2 (WH/RD) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to +Ve Voltage. A. Turn the keystart ON. Measure the voltage between connector: X-186 pin 1 (WH/OR) and ground X-186 pin 2 (WH/RD) and ground If a short to +Ve voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2088-5-8 range synchroniser solenoid - short to 12V Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Transmission disabled Possible failure modes: 1. Faulty connectors 2. Faulty 5-8 synchroniser solenoid 3. Faulty harness 4. Faulty controller Solution: 1. Check the 5-8 synchroniser solenoid connector X-187, the controller connectors X-240 and X-220 and the inline harness connector X-300. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connector is okay, continue to step 2 2. Check the 5-8 synchroniser solenoid for short to ground. A. Disconnect connector X-187. Check between the component side of connector: X-187 pin 1 and ground X-187 pin 2 and ground If a short to ground is indicated, replace the 5-8 synchroniser solenoid. B. If a short to ground is not indicated, continue to step 3 3. Check for a short to ground. A. Disconnect connector X-240 and X-220. Check between connector: X-187 pin 1 (WH/BL) and ground X-187 pin 2 (WH/YE) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to +Ve voltage. A. Turn the keystart ON. Measure the voltage between connector: X-187 pin 1 (WH/BL) and ground X-187 pin 2 (WH/YE) and ground If a short to +Ve voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2089-CAN-Bus - invalid engine speed Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty crankshaft speed sensor 3. Mechanical fault Solution: 1. Check for other error codes being displayed. A. If any other error code is being displayed, continue to these tests. B. If no other error code is displayed, continue to step 2 2. Check the crankshaft speed sensor connector X-965.,the engine control unit (ECU) connector X-939 and connector X-941 A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the crankshaft speed sensor. A. If installed incorrectly, loose or damaged, refit correctly or replace as required. B. If the sensor is installed correctly, remove and replace the crankshaft speed sensor. If fault is still present, possible fault with the speed sensor inductive ring.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

2090-CAN-Bus - ADIC absent Control Module : CCU Cause: No exchange of fault codes and information between the controllers. Possible failure modes: 1. Broken wiring. 2. Faulty connectors 3. Faulty controller Solution: 1. Disconnect the connectors from the various controllers: X-200 from the central control unit ( CCU), pin 15 and 16 X-450 from the analog-digital instrument cluster ( ADIC), pin 3 and 4 and check the diagnostics connector X-376, pin C and D A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the continuity of the wiring: A. Check continuity on the cable CAN1-A-L. X-200 from the central control unit ( CCU), pin 16, wire 0.75 (GN) to the analog-digital instrument cluster ( ADIC) X-450 pin 4, wire 0.75 (GN) X-200 from the central control unit ( CCU), pin 16, wire 0.75 (GN) to the diagnostics connector X-376 pin D, wire 0.75 (GN) Check continuity on the cable CAN1-A-H. X-200 from the central control unit ( CCU), pin 15, wire 0.75 (YE) to the analog-digital instrument cluster ( ADIC) X-450 pin 3, wire 0.75 (YE) X-200 from the central control unit ( CCU), pin 15, wire 0.75 (YE) to the diagnostics connector X-376 pin C, wire 0.75 (YE)If there is no continuity, repair or replace the wiring harness as necessary. B. If there is continuity, continue to step 3 3. Check the terminators of the CAN line: A. Measure the resistance of the terminators: X-200 between pin 16 and pin 15 X-450 between pin 3 and pin 4, is the resistance 120 ÎŠ. B. If the terminators are okay, continue to step 4 4. Check the total resistance of the CAN line: A. Reconnect all the controllers Measure the resistance on the diagnostic connector: X-376, between pins D and pin C, the resistance should be approximately 60 ÎŠ. B. If the total resistance of the terminators is okay, download the correct software release. If the error is repeated, remove and temporarily replace the central control unit ( CCU) and, if the error is repeated again, fit the central control unit ( CCU) back on and replace the analog-digital instrument cluster ( ADIC),

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Wire harnesses - Electrical schematic frame 11 (55.100.DP-C.20.E.11) Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15) Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

2091-Clutch 3 not calibrated Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Poor clutch performance of the non-calibrated clutch Cause: Possible failure modes: 1. Faulty clutch 3 solenoid 2. Faulty hydraulic circuit 3. Mechanical fault Solution: 1. Perform the transmission calibration procedure using the H1 menu. A. If the error code is still displayed, continue to step 2 2. Check for other error codes being displayed. A. If any other error codes are being displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check the solenoid of the faulty clutch. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, check the clutch pack pressures by carrying out a pressure test on the hydraulic system.

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Electrical systems - FAULT CODES

2092-Clutch 4 not calibrated Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Poor clutch performance of the non-calibrated clutch Cause: Possible failure modes: 1. Faulty clutch 4 solenoid 2. Faulty hydraulic circuit 3. Mechanical fault Solution: 1. Perform the transmission calibration procedure using the H1 menu. A. If the error code is still displayed, continue to step 2 2. Check for other error codes being displayed. A. If any other error codes are being displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check the solenoid of the faulty clutch. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, check the clutch pack pressures by carrying out a pressure test on the hydraulic system.

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Electrical systems - FAULT CODES

2095-Clutch 1 not calibrated Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Poor clutch performance of the non-calibrated clutch Cause: Possible failure modes: 1. Faulty clutch 1 solenoid 2. Faulty hydraulic circuit 3. Mechanical fault Solution: 1. Perform the transmission calibration procedure using the H1 menu. A. If the error code is still displayed, continue to step 2 2. Check for other error codes being displayed. A. If any other error codes are being displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check the solenoid of the faulty clutch. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, check the clutch pack pressures by carrying out a pressure test on the hydraulic system.

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Electrical systems - FAULT CODES

2096-Clutch 2 not calibrated Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Poor clutch performance of the non-calibrated clutch Cause: Possible failure modes: 1. Faulty clutch 2 solenoid 2. Faulty hydraulic circuit 3. Mechanical fault Solution: 1. Perform the transmission calibration procedure using the H1 menu. A. If the error code is still displayed, continue to step 2 2. Check for other error codes being displayed. A. If any other error codes are being displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check the solenoid of the faulty clutch. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, check the clutch pack pressures by carrying out a pressure test on the hydraulic system.

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Electrical systems - FAULT CODES

2110-Voltage from Shuttle lever Neutral switch too low Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty momentary shuttle lever 3. Faulty harness 4. Faulty controller Solution: 1. Check the momentary shuttle lever neutral switch in H5. A. Turn the ignition key switch ON. Depress the clutch pedal and move the shuttle lever into forward or reverse, d15 or d16 should be displayed. Press the shuttle lever neutral button, d24 should be displayed. If the display does not change to d24, continue to step 2 B. If the display does change correctly, while still in H5 wiggle the harness, the shuttle lever connector X-318 and controller connectors X-210 , X-230 and X-240 to check for an intermittent circuit. The display will change if an intermittent circuit is detected, repair or replace as required. 2. Check for 12 V. A. Disconnect connector X-318. Turn the ignition key switch ON. Measure the voltage between connector X-318 pin 5 (OR/WH) and ground. If approximately 12 V is not indicated, repair or replace the harness as required. B. If approximately 12 V is indicated, continue to step 3 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect the controller connector X-230. Check between X-230 pin 13 (TQ/WH) and X-318 pin 11 (TQ/W). If an open circuit is indicated, repair or replace the harness as required. If an open circuit is not indicated, continue to step 4 4. Check for a short to ground. A. Check between connector X-230 pin 13 (TQ/WH) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the momentary shuttle lever. If the fault is still present, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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Electrical systems - FAULT CODES

2111-Voltage from Shuttle lever Neutral switch too high Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty momentary shuttle lever 3. Faulty harness 4. Faulty controller Solution: 1. Check the momentary shuttle lever neutral switch in H5. A. Turn the ignition key switch ON. Depress the clutch pedal and move the shuttle lever into forward or reverse, d15 or d16 should be displayed. Press the shuttle lever neutral button, d24 should be displayed. If the display does not change to d24, continue to step 2 B. If the display does change correctly, while still in H5 wiggle the harness, the shuttle lever connector X-318 and controller connectors X-210 , X-230 and X-240 to check for an intermittent circuit. The display will change if an intermittent circuit is detected, repair or replace as required. 2. Check for 12 V. A. Disconnect connector X-318. Turn the ignition key switch ON. Measure the voltage between connector X-318 pin 5 (OR/WH) and ground. If approximately 12 V is not indicated, repair or replace the harness as required. B. If approximately 12 V is indicated, continue to step 3 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect the controller connector X-230. Check between connector X-230 pin 13 (TQ/WH) and X-318 pin11 (TQ/WH). If an open circuit is indicated, repair or replace the harness as required. If an open circuit is not indicated, continue to step 4 4. Check for a short to positive. A. Turn the ignition key switch ON. Measure the voltage between connector X-230 pin 13 (TQ/WH) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the momentary shuttle lever. If the fault is still present, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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Electrical systems - FAULT CODES

4500-Electro Hydraulic Remote valve (EHR) front 1 - no control message received Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty central control unit ( CCU) software 4. Faulty EHR valve Solution: 1. Check the EHR valve connector X-396 and the central control unit ( CCU) connector X-200. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check for +12 Volts. A. Disconnect connector X-396. Turn the ignition key switch ON. Measure the voltage between connector X-396 pin 1 (YE/GN) and ground. If the voltage indicated is not approximately +12 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately +12 Volts, continue to step 3 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect the central control unit ( CCU) connector X-200. Measure the resistance between the connectors: X-396 pin 2 (BL) and X-200 pin 22 (BL) X-396 pin 3 (RD) and X-200 pin 21 (RD) X-396 pin 4 (BK/WH) and ground If the resistance indicated is greater than 5 Ohms, repair or replace the harness as required. B. If the resistance indicated is less than 5 Ohms, continue to step 4 4. Check for a short to ground. A. Check between connector: X-396 pin 1 (YE/GN) and ground X-396 pin 2 (BL) and ground X-396 pin 3 (RD) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for an open CAN circuit. A. Measure the resistance between connector X-396 pin 2 (BL) and X-396 pin 3 (RD). If the resistance indicated is not approximately 120 Ohms, repair or replace the harness as required to the CAN resistor X-398. B. If the harness is okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 11 (55.100.DP-C.20.E.11) Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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Electrical systems - FAULT CODES

4501-Electro Hydraulic Remote valve (EHR) front 1 - control message not plausible Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty central control unit ( CCU) software 4. Faulty EHR valve Solution: 1. Check the EHR valve connector X-396 and the central control unit ( CCU) connector X-200. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check for +12 Volts. A. Disconnect connector X-396. Turn the ignition key switch ON. Measure the voltage between connector X-396 pin 1 (YE/GN) and ground. If the voltage indicated is not approximately +12 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately +12 Volts, continue to step 3 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect the central control unit ( CCU) connector X-200. Measure the resistance between the connectors: X-396 pin 2 (BL) and X-200 pin 22 (BL) X-396 pin 3 (RD) and X-200 pin 21 (RD) X-396 pin 4 (BK/WH) and ground If the resistance indicated is greater than 5 Ohms, repair or replace the harness as required. B. If the resistance indicated is less than 5 Ohms, continue to step 4 4. Check for a short to ground. A. Check between connector: X-396 pin 1 (YE/GN) and ground X-396 pin 2 (BL) and ground X-396 pin 3 (RD) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for an open CAN circuit. A. Measure the resistance between connector X-396 pin 2 (BL) and X-396 pin 3 (RD). If the resistance indicated is not approximately 120 Ohms, repair or replace the harness as required to the CAN resistor X-398. B. If the harness is okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 11 (55.100.DP-C.20.E.11) Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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Electrical systems - FAULT CODES

4502-Electro Hydraulic Remote valve (EHR) front 1 - EEPROM fault Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Driveline oil temperature too high 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the driveline oil temperature. A. If the oil temperature is greater than 115 Â°C, clean the oil cooler and radiator fins and make sure there is no air flow restriction. Allow the driveline oil temperature to cool. B. If the harness is okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4503-Electro Hydraulic Remote valve (EHR) front 1 - switched to failsafe Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Other EHR error code(s) detected. 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. If any other error codes are still displayed, continue to these tests. B. If only error code 4503 is still displayed, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4504-Electro Hydraulic Remote valve (EHR) front 1 - under-voltage Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty central control unit ( CCU) software 4. Faulty EHR valve Solution: 1. Check the EHR valve connector X-396 and the inline harness connector X-188. A. Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connector is okay, continue to step 2 2. Check for +12 Volts. A. Disconnect the inline harness connector X-188. Turn the ignition key switch ON. Measure the voltage between connector X-188 pin 12 (YE/GN) and ground. If the voltage indicated is less than approximately +8 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately +12 Volts, continue to step 3 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect the connector X-396. Measure the resistance between connector: X-396 pin 1 (YE/GN) and X-188 pin 12 (YE/GN) X-396 pin 4 (BK/WH) and ground If the resistance indicated is greater than 5 Ohms, repair or replace the harness as required. B. If the resistance indicated is okay, continue to step 4 4. Check for a short to ground. A. Check between connector X-396 pin 1 (YE/GN) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04) Wire harnesses - Electrical schematic frame 11 (55.100.DP-C.20.E.11)

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Electrical systems - FAULT CODES

4505-Electro Hydraulic Remote valve (EHR) front 1 - over-voltage Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. External power supply connected 2. Faulty charging system 3. Faulty central control unit ( CCU) software 4. Faulty EHR valve Solution: 1. Check that the tractor battery power supply has not been connected to an external power supply. A. If an external power supply is connected to the tractor, disconnect and test the system for normal operation. B. If an external power supply is not connected to the tractor, continue to step 2 2. Check the battery voltage. A. Start the engine and run at 2000 rev/min. Measure the battery voltage. If the voltage indicated is greater than approximately +15 Volts, continue to test for a fault in the charging system. B. If the voltage indicated is between approximately +9 Volts and +15 Volts, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4506-Electro Hydraulic Remote valve (EHR) front 1 - spool movement too low Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Incorrect hydraulic pressure 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the hydraulic pressures. A. If the pressures are incorrect, repair or replace component(s) as required. B. If the pressures are okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4507-Electro Hydraulic Remote valve (EHR) front 1 - spool movement too high Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Incorrect hydraulic pressure 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the hydraulic pressures. A. If the pressures are incorrect, repair or replace component(s) as required. B. If the pressures are okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4508-Electro Hydraulic Remote valve (EHR) front 1 - float position not reached Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Incorrect hydraulic pressure 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the hydraulic pressures. A. If the pressures are incorrect, repair or replace component(s) as required. B. If the pressures are okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4509-Electro Hydraulic Remote valve (EHR) front 1 - manually operated Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Remote valve manually operated 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Calibrate the EHR lever. A. Perform the EHR lever calibration procedure and test the system for normal operation. B. If the fault is still present, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4511-Electro Hydraulic Remote valve (EHR) front 1 - potentiometer faulty Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Driveline oil temperature too high 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the driveline oil temperature. A. If the oil temperature is greater than 115 Â°C, clean the oil cooler and radiator fins and make sure there is no air flow restriction. Allow the driveline oil temperature to cool. B. If the oil temperature is okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4512-Electro Hydraulic Remote valve (EHR) front 1 - unable to reach neutral Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: Possible failure modes: 1. Driveline oil temperature too high 2. Driveline oil contamination 3. Incorrect hydraulic pressure 4. Faulty central control unit ( CCU) software 5. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the driveline oil temperature. A. If the oil temperature is greater than 115 Â°C, clean the oil cooler and radiator fins and make sure there is no air flow restriction. Allow the driveline oil temperature to cool. B. If the oil temperature is okay, continue to step 3 3. Check the driveline oil for contamination. A. If the oil is contaminated, replace as required. B. If the oil is not contaminated, continue to step 4 4. Check the hydraulic pressures. A. If the pressures are incorrect, repair or replace component(s) as required. B. If the pressures are okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4513-Electro Hydraulic Remote valve (EHR) front 1 - spool not in neutral at key on Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Ignition key switched off during EHR valve operation 2. Incorrect hydraulic pressure 3. Faulty central control unit ( CCU) software 4. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the hydraulic pressures. A. If the pressures are incorrect, repair or replace component(s) as required. B. If the pressures are okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4514-Electro Hydraulic Remote valve (EHR) front 2 - no control message received Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty central control unit ( CCU) software 4. Faulty EHR valve Solution: 1. Check the EHR valve connector X-397 and the central control unit ( CCU) connector X-200. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check for +12 Volts. A. Disconnect connector X-397. Turn the ignition key switch ON. Measure the voltage between connector X-397 pin 1 (YE/GN) and ground. If the voltage indicated is not approximately +12 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately +12 Volts, continue to step 3 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect the central control unit ( CCU) connector X-200. Measure the resistance between the connectors: X-397 pin 2 (BL) and X-200 pin 22 (BL) X-397 pin 3 (RD) and X-200 pin 21 (RD) X-397 pin 4 (BK/WH) and ground If the resistance indicated is greater than 5 Ohms, repair or replace the harness as required. B. If the resistance indicated is less than 5 Ohms, continue to step 4 4. Check for a short to ground. A. Check between connector: X-397 pin 1 (YE/GN) and ground X-397 pin 2 (BL) and ground X-397 pin 3 (RD) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for a open CAN circuit. A. Measure the resistance between connector X-397 pin 2 (BL) and X-397 pin 3 (RD). If the resistance indicated is not approximately 120 Ohms, repair or replace the harness as required to the CAN resistor X-398. B. If the harness is okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 11 (55.100.DP-C.20.E.11) Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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Electrical systems - FAULT CODES

4515-Electro Hydraulic Remote valve (EHR) front 2 - control message not plausible Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty central control unit ( CCU) software 4. Faulty EHR valve Solution: 1. Check the EHR valve connector X-397 and the central control unit ( CCU) connector X-200. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check for +12 Volts. A. Disconnect connector X-397. Turn the ignition key switch ON. Measure the voltage between connector X-397 pin 1 (YE/GN) and ground. If the voltage indicated is not approximately +12 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately +12 Volts, continue to step 3 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect the central control unit ( CCU) connector X-200. Measure the resistance between the connectors: X-397 pin 2 (BL) and X-200 pin 22 (BL) X-397 pin 3 (RD) and X-200 pin 21 (RD) X-397 pin 4 (BK/WH) and ground If the resistance indicated is greater than 5 Ohms, repair or replace the harness as required. B. If the resistance indicated is less than 5 Ohms, continue to step 4 4. Check for a short to ground. A. Check between connector: X-397 pin 1 (YE/GN) and ground X-397 pin 2 (BL) and ground X-397 pin 3 (RD) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for a open CAN circuit. A. Measure the resistance between connector X-397 pin 2 (BL) and X-397 pin 3 (RD). If the resistance indicated is not approximately 120 Ohms, repair or replace the harness as required to the CAN resistor X-398. B. If the harness is okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 11 (55.100.DP-C.20.E.11) Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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Electrical systems - FAULT CODES

4516-Electro Hydraulic Remote valve (EHR) front 2 - EEPROM fault Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Driveline oil temperature too high 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the driveline oil temperature. A. If the oil temperature is greater than 115 Â°C, clean the oil cooler and radiator fins and make sure there is no air flow restriction. Allow the driveline oil temperature to cool. B. If the oil temperature is okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4517-Electro Hydraulic Remote valve (EHR) front 2 - switched to failsafe Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Other EHR error code(s) detected. 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. If any other error codes are still displayed, continue to these tests. B. If only error code 4517 is still displayed, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4518-Electro Hydraulic Remote valve (EHR) front 2 - under-voltage Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty central control unit ( CCU) software 4. Faulty EHR valve Solution: 1. Check the EHR valve connector X-397 and the inline harness connector X-188. A. Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connector is okay, continue to step 2 2. Check for +12 Volts. A. Disconnect the inline harness connector X-188. Turn the ignition key switch ON. Measure the voltage between connector X-188 pin 12 (YE/GN) and ground. If the voltage indicated is less than approximately +8 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately +12 Volts, continue to step 3 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect the connector X-397. Measure the resistance between connector: X-397 pin 1 (YE/GN) and X-188 pin 12 (YE/GN) X-397 pin 4 (BK/WH) and ground If the resistance indicated is greater than 5 Ohms, repair or replace the harness as required. B. If the resistance indicated is okay, continue to step 4 4. Check for a short to ground. A. Check between connector X-397 pin 1 (YE/GN) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

4519-Electro Hydraulic Remote valve (EHR) front 2 - over-voltage Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. External power supply connected 2. Faulty charging system 3. Faulty central control unit ( CCU) software 4. Faulty EHR valve Solution: 1. Check that the tractor battery power supply has not been connected to an external power supply. A. If an external power supply is connected to the tractor, disconnect and test the system for normal operation. B. If an external power supply is not connected to the tractor, continue to step 2 2. Check the battery voltage. A. Start the engine and run at 2000 rev/min. Measure the battery voltage. If the voltage indicated is greater than approximately +15 Volts, continue to test for a fault in the charging system. B. If the voltage indicated is between approximately +9 Volts and +15 Volts, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4520-Electro Hydraulic Remote valve (EHR) front 2 - spool movement too low Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Incorrect hydraulic pressure 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the hydraulic pressures A. If the pressures are incorrect, repair or replace component(s) as required. B. If the pressures are okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4521-Electro Hydraulic Remote valve (EHR) front 2 - spool movement too high Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Incorrect hydraulic pressure 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the hydraulic pressures. A. If the pressures are incorrect, repair or replace component(s) as required. B. If the pressures are okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4522-Electro Hydraulic Remote valve (EHR) front 2 - float position not reached Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Incorrect hydraulic pressure 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the hydraulic pressures. A. If the pressures are incorrect, repair or replace component(s) as required. B. If the pressures are okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4523-Electro Hydraulic Remote valve (EHR) front 2 - manually operated Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Remote valve manually operated 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Calibrate the EHR lever. A. Perform the EHR lever calibration procedure and test the system for normal operation. B. If the fault is still present, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4525-Electro Hydraulic Remote valve (EHR) front 2 - potentiometer faulty Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Driveline oil temperature too high 2. Faulty central control unit ( CCU) software 3. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the driveline oil temperature. A. If the oil temperature is greater than 115 Â°C, clean the oil cooler and radiator fins and make sure there is no air flow restriction. Allow the driveline oil temperature to cool. B. If the oil temperature is okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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Electrical systems - FAULT CODES

4526-Electro Hydraulic Remote valve (EHR) front 2 - unable to reach neutral Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Driveline oil temperature too high 2. Driveline oil contamination 3. Incorrect hydraulic pressure 4. Faulty central control unit ( CCU) software 5. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the driveline oil temperature. A. If the oil temperature is greater than 115 Â°C, clean the oil cooler and radiator fins and make sure there is no air flow restriction. Allow the driveline oil temperature to cool. B. If the oil temperature is okay, continue to step 3 3. Check the driveline oil for contamination. A. If the oil is contaminated, replace as required. B. If the oil is not contaminated, continue to step 4 4. Check the hydraulic pressures. A. If the pressures are incorrect, repair or replace component(s) as required. B. If the pressures are okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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4527-Electro Hydraulic Remote valve (EHR) front 2 - spool not in neutral at key on Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Ignition key switched off during EHR valve operation 2. Incorrect hydraulic pressure 3. Faulty central control unit ( CCU) software 4. Faulty EHR valve Solution: 1. Check for other EHR error code(s). A. Make a note of the error code(s), clear the error code(s) and test the system for normal operation. B. If the fault is still present, continue to step 2 2. Check the hydraulic pressures. A. If the pressures are incorrect, repair or replace component(s) as required. B. If the pressures are okay, download the correct level of software into the central control unit ( CCU) and configure the EHR valve using the HJ menu. If the fault is still present remove, replace, and configure the EHR valve using the HJ menu.

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5001-Rear PTO brake solenoid error Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation Possible failure modes: 1. Faulty connectors 2. PTO brake solenoid valve faulty 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the PTO brake solenoid valve connector X-189, the transmission - cab main connector X-300, and the connector of the central control unit ( CCU) X-240. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the PTO brake solenoid valve. A. Disconnect the connector X-189. Measure the resistance between the component side of connector: X-189 between pins 1 and 2 If the resistance indicated is not approximately 7.0 - 7.6 ÎŠ, remove and replace the brake solenoid valve. B. If the resistance indicated is approximately 7.0 - 7.6 ÎŠ, continue to step 3 3. Check the PTO brake solenoid valve for a short to ground. A. Check between the component side of connector: X-189 pin 1 and ground X-189 pin 2 and ground If a short to ground is indicated, remove and replace the brake solenoid valve. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to ground. A. Disconnect the connector X-240. Check between: X-189 pin 1, wire 1.0 (BR/WH) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for an open circuit. A. Check between: X-189 pin 1, wire 1.0 (BR/WH) and X-240 pin 8, wire 0.5 (BR/WH) X-189 pin 2, wire 1.0 (BK) and ground If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, go to 6 6. Check for a short to positive voltage A. Turn the ignition key to ON position. Check between: X-189 pin 1, wire 1.0 (BR/WH) and ground X-189 pin 2, wire 1.0 (BK) and ground If a positive voltage is indicated,repair or replace the harness as required. 47538922 29/05/2013

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B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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5005-Rear PTO brake switch error Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation Possible failure modes: 1. Faulty connector 2. PTO brake switch faulty 3. Auto PTO switch faulty 4. Wiring fault 5. Central control unit ( CCU) fault Solution: 1. Check the PTO brake switch connector X-351, the auto PTO switch connector X-190 , and the connectors of the central control unit ( CCU) X-230 and X-240 . A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the PTO brake switch A. Disconnect connector X-351 and check on the component side. Check there is continuity between X-351 pin 2 and X-351 pin 4, when switch is released Check there is not continuity between X-351 pin 2 and X-351 pin 4, when switch is pressed. Repair or replace as required B. If the PTO brake switch is okay, continue to step 3 3. Check for the correct power voltage of the auto PTO switch connector ( 12 V ) A. Disconnect the auto PTO switch connector X-190. Turn the ignition key switch ON and check between: X-190 pin 5, wire 0.5 (GY/BL) and ground If a voltage of approximately 12 V is not indicated ,repair or replace the harness as required. B. If a voltage of approximately 12 V is indicated ,continue to 4 4. Check for a voltage of approximately 12 V A. Turn of the ignition key switch, connect the connector X-190 and turn on the ignition key switch, with the connector X-190 connected, measure the voltage at the back of connector X-190 pin 1â&#x20AC;&#x2122; Check for 12 V with the auto PTO switch operating, check between X-190 pin 1, wire 0.5 (OR/WH) and ground If the voltage is not approximately 12 V Replace the auto PTO switch B. If approximately 12 V is indicated,continue to 5 5. Check for a short to ground A. Disconnect the connector X-230 and X-351 . Check connectors between: X-230 pin 8, wire 0.5 (OR/WH) and ground X-190 pin 1, wire 0.5 (OR/WH) and ground If a short to ground is indicatedrepair or replace the harness as required. B. If the harness is okay, continue to 6 6. Check for an open circuit

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A. Check between: X-190 pin 1, wire 0.5 (OR/WH) and X-351 pin 2, wire 0.5 (OR/WH) X-351 pin 4, wire 0.5 (OR/WH) and X-230 pin 8, wire 0.5 (OR/WH) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, continue to download the correct level of software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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5008-Rear PTO clutch solenoid - open circuit error Control Module : CCU Cause: Short to ground or open circuit between the PTO clutch solenoid valve and the control unit ( CCU), or the solenoid valve is faulty. Possible failure modes: 1. Faulty connectors 2. PTO clutch solenoid valve faulty 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the PTO clutch solenoid valve connector X-344, the transmission - cab main connector X-300 , and the connector of the central control unit ( CCU) X-240. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the PTO clutch solenoid valve. A. Disconnect the connector X-344. Measure the resistance between the component side of connector: X-344 between pins 1 and 2 If the resistance indicated is not approximately 8 ÎŠ, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 3 3. Check the PTO solenoid valve for a short to ground. A. Check between the component side of connector: X-344 pin 1 and ground X-344 pin 2 and ground If a short to ground is indicated, remove and replace the clutch solenoid valve. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to ground. A. Disconnect the connector X-240. Check between: X-344 pin 1, wire 1.0 (OR/BK) and ground X-344 pin 2, wire 1.0 (BR/GN) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for an open circuit. A. Check between: X-344 pin 1, wire 1.0 (OR/BK) and X-240 pin 14, wire 0.5 (OR/BK) X-344 pin 2, wire 1.0 (BR/GN) and X-240 pin 18, wire 0.5 (BR/GN) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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5027-Rear PTO speed sensor - open circuit error Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: PTO disabled. Possible failure modes: 1. Faulty connector 2. Faulty rear PTO speed sensor 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the rear PTO speed sensor connector X-341, the transmission - cab main connector X-300 and the connector of the central control unit ( CCU) X-240. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check for 12 Volts. A. Disconnect connector X-341. Turn the ignition key switch ON. Measure the voltage between connector X-341 pin 1, wire 1.0 (GY/BL) and ground. If approximately 12 Volts is not indicated, repair or replace the harness as required. B. If approximately 12 Volts is indicated, continue to step 3 3. Check for an open ground circuit. A. Check between connector X-341 pin 3, wire 1.0 (BK/WH) and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 4 4. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connector X-240. Check between connector X-240 pin 19, wire 0.5 (BR/WH) and connector X-341 pin 2, wire 1.0 (BR/WH). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for a short to positive. A. Turn the ignition key switch ON. Measure the voltage between connector X-341 pin 2, wire 1.0 (BR/WH) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the rear PTO speed sensor. If the error is still present, download the correct level of software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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5033-Rear PTO cab normally closed switch error Control Module : CCU Context: Effects: PTO disabled. Possible failure modes: 1. Faulty connectors 2. Faulty PTO switch 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the PTO cab switch connector X-350 and the connector of the central control unit ( CCU) X-240. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the PTO cab switch. A. Disconnect the PTO cab switch connector X-350. Operating the switch, check between: X-350 pin 1 and X-350 pin 3 The indication must be: approximately 3900 Ω when disengaged; an open circuit when engaged and an open circuit when only the yellow button is pressed. X-350 pin 1 and X-350 pin 2 The indication must be: an open circuit when disengaged; approximately 3900 Ω when engaged and an open circuit when only the yellow button is pressed. X-350 pin 2 and X-350 pin 3 An open circuit must be indicated when disengaged, engaged or when only the yellow button is pressed. If the switch operation is not as indicated, remove and replace the PTO switch. B. If the switch is okay, continue to step 3 3. Check for a short to + 12 V. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-350 pin 1, wire 0.5 (GY/BL) and ground If the indicated voltage is not + 12 V, repair or replace the harness as required. B. If + 12 V is indicated, continue to step 4 4. Check for an open circuit. A. Turn ignition key switch to OFF position. Disconnect the connector of the central control unit ( CCU) X-240. Check between the connector: X-350 pin 3, wire 0.5 (GY) and X-240 pin 23, wire 0.5 (GY) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicate, continue to step 5 5. Check for a short to ground. A. Check between the connector: X-240 pin 23, wire 0.5 (GY) and ground If a short to ground is indicated, repair or replace the harness as required.

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B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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5034-Rear PTO fender switch - open circuit / short to ground Control Module : CCU Context: Effects: PTO disabled. With the key ON and pressing the PTO fender switch(es) the central control unit ( CCU ) signals a fault: Possible failure modes: 1. Effects: PTO disabled. With the key ON and pressing the PTO fender switch(es) the central control unit ( CCU ) signals a fault: 2. Wiring fault 3. Central control unit ( CCU ) fault Solution: 1. Check the connector of the central control unit ( CCU) X-230 and the connector of the PTO fender switches X-347 and X-349. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the PTO fender switches. A. Disconnect both PTO fender switches X-349 and X-347. Using a tester switched onto continuity tests, check whether between: X-347 and X-349 pin 1 and pin 2 there is continuity X-347 and X-349 pin 1 and pin 3 there is continuity only by pressing the button B. If the PTO fender switches work properly, pass on to point 3, otherwise replace the PTO fender switch(es). 3. Check power supply. A. Using a tester, switched onto voltmeter, check that: with one rod to ground and the other on the left-hand PTO fender switch connection X-347 pin 1, wire 0.5 (GY/BL) there is a voltage of + 12 V. Check that there is no continuity between: X-349 on pin 2, wire 0.5 (BR/BK) and X-347 on pin 1, wire 0.5 (GY/BL). B. If this condition is met pass on to step 4, otherwise repair the wiring or, if necessary, replace the fuse F010 ( 10 A). 4. Disconnect the connector X-230, check short circuit to ground. A. Using a tester test the continuity with a rod on the connector: X-230 pin 20, wire 0.5 (BR/BK) and ground X-230 pin 21, wire 0.5 (OR) and ground If a short to ground is indicated, repair or replace the harness as required. 5. Check for an open circuit. A. Check between the connectors: X-230 pin 20, wire 0.5 (BR/BK) and X-349 pin 2, wire 0.5 (BR/BK) X-230 pin 21, wire 0.5 (OR) and X-349 pin 3, wire 0.5 (OR) X-230 pin 21, wire 0.5 (OR) and X-347 pin 3, wire 0.5 (OR) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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5035-Rear PTO fender switch - input short to 12V Control Module : CCU Context: Effects: PTO disabled. With the key ON and pressing the PTO fender switch(es) the central control unit ( CCU) signals a fault: Possible failure modes: 1. Faulty PTO fender switch(es) 2. Wiring fault 3. Central control unit ( CCU) fault Solution: 1. Disconnect the connector of the central control unit ( CCU) X-230 and the connector of the PTO fender switches X-347 and X-349. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the PTO fender switches. A. Disconnect both PTO fender switches X-349 and X-347. Using a tester switched onto continuity tests, check whether between: X-347 and X-349 pin 1 and pin 2 there is continuity X-347 and X-349 pin 1 and pin 3 there is continuity only by pressing the button B. If the PTO fender switches work properly, pass on to step 3 C. otherwise replace the PTO fender switch(es). 3. Check for a short to + 12 V. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: X-349 pin 2, wire 0.5 (BR/BK) and ground X-349 pin 3, wire 0.5 (OR) and ground If positive voltage is detected, turn the key OFF. Disconnect the connector X-230 Turn the key ON and try again. If voltage is still indicated, repair or replace the harness as required. B. If no voltage is indicated, download the correct level of software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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5037-Rear PTO cab switch normally open error Control Module : CCU Context: Effects: PTO disabled. Possible failure modes: 1. Faulty PTO switch 2. Wiring fault 3. Central control unit ( CCU) fault Solution: 1. Check the PTO cab switch. A. Disconnect the PTO cab switch connector X-350. Operating the switch, check between: X-350 pin 1 and X-350 pin 3 The indication must be: approximately 3900 Ω when disengaged; an open circuit when engaged and an open circuit when only the yellow button is pressed. X-350 pin 1 and X-350 pin 2 The indication must be: an open circuit when disengaged; approximately 3900 Ω when engaged and an open circuit when only the yellow button is pressed. X-350 pin 2 and X-350 pin 3 An open circuit must be indicated when disengaged, engaged or when only the yellow button is pressed. If the switch operation is not as indicated, remove and replace the PTO switch. B. If the switch is okay, continue with step 2 2. Check for a short circuit. A. Disconnect the connector of the central control unit ( CCU) X-240. Check between the connector: X-350 pin 3, wire 0.5 (GY) and X-350 pin 2, wire 0.5 (BR/VT) If a short circuit is indicated, repair or replace the harness as required. B. If a short circuit is not indicated, continue to step 3 3. Check for short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-350 pin 2, wire 0.5 (BR/VT) and ground If voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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5043-Rear PTO fender switch stuck on error Control Module : CCU Context: Effects: PTO disabled. Possible failure modes: 1. Faulty PTO fender switch(es) 2. Wiring fault 3. Central control unit ( CCU) fault NOTE: If the error appears following an incorrect operation of starting the power take--off with the PTO fender switch(es), proceed as follows: - Continue pressing the PTO fender switch for longer than 12 s (the control unit shuts down the PTO and makes the warning light blink) - Try again, pressing the switch, for longer than 10 s (the control unit disables the PTO and signals the relevant fault code). Simply switch off the machine and switch it back on again, proceeding as follows to start up the power take--off with the PTO fender switch. Brief movement of the shaft to align the grooves. - Briefly press the switch (for less than 5 s) to make the shaft turn gradually and the movement will stop when the switch is released. Start up the PTO with the fender switches. - Press the switch (for less than 12 s but longer than 5 s) to make the shaft turn, press the switch again to stop the shaft. If the error appears following a correct operation of starting the power–takeoff, proceed as follows. Solution: 1. Check the switches X-349 and X-347 in the HH programs on the control unit RI in program H5. A. Press and release the switches on both fenders, the display must show alternately codes d63 and d64, if there is no alternation continue to step 2 B. If the alternation is okay, while still in H5, wiggle the harness, the connectors of the switches X-349 and X-347 and the connectors of the control unit ( CCU) X-230 to check for an intermittent circuit. The values displayed will change if an intermittent circuit is detected. Repair or replace as required. 2. Disconnect the connector of the control unit ( XCM) X-230 and the connector of the PTO fender switches X-347 and X-349. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the PTO fender switches. A. Disconnect both PTO fender switches X-349 and X-347. Using a tester switched onto continuity tests, check whether between: X-347 and X-349 pin 1 and pin 2 there is continuity X-347 and X-349 pin 1 and pin 3 there is continuity only by pressing the button B. If the PTO fender switches work properly, pass on to point 4, otherwise replace the PTO fender switch(es). 4. Check for a short to + 12 V. A. Turn the ignition key switch ‘ON’. Measure the voltage between the connector: X-349 pin 2, wire 0.5 (BR/BK) and ground X-349 pin 3, wire 0.5 (OR) and ground 47538922 29/05/2013

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If positive voltage is detected, turn the key OFF. Disconnect the connector X-230. Turn the ignition key switch ON and try again. If voltage is still indicated, repair or replace the harness as required. B. If no voltage is indicated, download the correct level of software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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5044-Rear PTO speed sensor - short to ground Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: PTO disabled. Possible failure modes: 1. Faulty connector 2. Faulty rear PTO speed sensor 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the rear PTO speed sensor connector X-341, the transmission - cab main connector X-300 and the connector of the central control unit ( CCU) X-240. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check for 12 Volts. A. Disconnect connector X-341. Turn the ignition key switch ON. Measure the voltage between connector X-341 pin , wire 1.0 (GY/BL) and ground. If approximately 12 Volts is not indicated, repair or replace the harness as required. B. If approximately 12 Volts is indicated, continue to step 3 3. Check for an open ground circuit. A. Check between connector X-341 pin 3, wire 1.0 (BK/WH) and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 4 4. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connector X-240. Check between connector X-240 pin 19, wire 0.5 (BR/WH) and connector X-341 pin 2, wire 1.0 (BR/WH). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for a short to ground. A. Check between connector X-341 pin 2, wire 1.0 (BR/WH) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 6 6. Check for an short circuit. A. Check between connector X-341 pin 2, wire 1.0 (BR/WH) and X-341 pin 3, wire 1.0 (BK(WH). If a short circuit is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the rear PTO speed sensor. If the error is still present, download the correct level of software. If the error is repeated, remove and replace the central control unit ( CCU). 47538922 29/05/2013

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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5045-Ground speed PTO switch open / short to ground Control Module : CCU Possible failure modes: 1. Faulty ground speed PTO switch 2. Wiring fault 3. Central control unit ( CCU) fault Solution: 1. Check the ground speed PTO switch X-352 in H9, RI module, channel 138. A. Operate the ground speed PTO switch. If the values displayed do not change to approximately 3410 mV on engaging the switch and 1510 mV with the switch disengaged, continue to step 2 B. If the values displayed are okay, while still in H9, channel 138, wiggle the harness, the ground speed PTO switch connector X-352, the transmission - cab main connector X-300, and the connectors of the central control unit ( CCU) X-230 and X-210 to check for an intermittent circuit, Channel 138 values will change if an intermittent circuit is detected. Repair or replace as required. 2. Check the ground speed PTO switch connector X-352, the transmission - cab main connector X-300, and the connectors of the central control unit ( CCU) X-230 and X-210. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the + 5 V power supply. A. Disconnect the ground speed PTO switch connector X-352. Turn the ignition key switch ‘ON’. Measure the voltage between the connector: X-352 pin 1, wire 1.0 (TQ/WH) and ground If approximately + 5 V is not indicated, repair or replace the harness as required. B. If approximately + 5 V is indicated, continue to step 4 4. Check the ground speed PTO switch X-352. A. Disconnect the connector X-352. Measure the resistance between: X-352 pin 1 and pin 2. With the lever of the ground speed PTO disengaged, it should indicate 2760 Ω. X-352 pin 1 and pin 2. With the lever of the ground speed PTO engaged, it should indicate 560 Ω. If the resistances indicated are not okay, remove and replace the switch. B. If the ground speed PTO switch is okay, continue to step 5 5. Check for an open circuit. A. Disconnect the connectors X-230 and X-210. Check between: X-352 pin 1, wire 1.0 (TQ/WH) and X-210 pin 17, wire 1.0 (TQ/WH) X-352 pin 2, wire .1.0 (GN) and X-230 pin 17, wire 0.5 (GN) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicate, continue to step 6 6. Check for a short to ground. A. Check between connector X-230 pin 17, wire 0.5 (GN) and ground If a short to ground is indicated, repair or replace the harness as required. 47538922 29/05/2013

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B. If the harness is okay, continue to download the correct level of software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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5046-Ground speed PTO switch short to 12V Control Module : CCU Context: Cause: Short to a voltage between the ground speed PTO switch and the central control unit ( CCU), or the switch is faulty.

Possible failure modes: 1. Faulty ground speed PTO switch 2. Wiring fault 3. Central control unit ( CCU) fault Solution: 1. Check the ground speed PTO switch X-352 in H9, channel 138. A. Operate the ground speed PTO switch. If the values displayed do not change to approximately 3410 mV on engaging the switch and 1510 mV with the switch disengaged, continue to step 2 B. If the values displayed are okay, while still in H9, channel 138, wiggle the harness, the ground speed PTO switch connector X-352, the transmission - cab main connector X-300, and the connectors of the central control unit ( CCU) X-230 and X-210 to check for an intermittent circuit, Channel 138 values will change if an intermittent circuit is detected. Repair or replace as required. 2. Check the ground speed PTO switch X-352, the transmission - cab main connector X-300, and the connectors of the central control unit ( CCU) X-230 and X-210. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the ground speed PTO switch X-352. A. Disconnect the connector X-352. Measure the resistance between: X-352 pin 1 and pin 2. With the lever of the ground speed PTO disengaged, it should indicate 2760 Ω. X-352 pin 1 and pin 2. With the lever of the ground speed PTO engaged, it should indicate 560 Ω. If the resistances indicated are not okay remove and replace the switch. B. If the switch is okay, continue to step 4 4. Check for a short to positive. A. Disconnect the connector of the control unit X-230. Turn the ignition key switch ‘ON’. Measure the voltage between the connector: X-230 pin 17, wire 0.5 (GN) and ground If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 5 5. Check for a short to + 8 V or + 12 V. A. With the ignition switch key ON. Measure the voltage between the connector: X-352 pin 1, wire 1.0 (TQ/WH) and ground If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. B. If the voltage is approximately + 5 V, download the correct level of software. If the error is repeated, remove and replace the central control unit ( CCU). 47538922 29/05/2013

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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5047-Ground speed PTO configuration error Control Module : CCU Cause: The central control unit ( CCU) has detected the presence of ground speed PTO but the option has not been enabled or the ground speed PTO has been enabled but the option is not fitted on the machine. Solution: 1. Check that ground speed PTO is fitted to the machine and has been enabled. A. Enter the HH MENU programs of the control unit ( ADIC), in RI, H3, Channel 5, select YES to enable the ground speed PTO option if fitted or NO to disable if not fitted. NOTE: To enter the HH MENU programs, refer to dedicated chapter in this manual.

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5098-Rear PTO fender switch option not enabled Control Module : CCU Cause: The central control unit ( CCU) has detected the presence of rear PTO fender switches but the option has not been has not been enabled. Solution: 1. Check that the rear PTO fender switches have been enabled. A. Enter the HH MENU programs of the control unit ( ADIC), in RI, H3, Channel 2, select YES to enable the rear PTO fender switches. NOTE: To enter the HH MENU programs, refer to the dedicated chapter in this manual.

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5099-Rear PTO Auto PTO not enabled Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation Cause: The central control unit ( CCU) has detected the presence of rear auto PTO but the option has not been enabled. Solution: 1. Check that the rear auto PTO has been enabled. A. Enter the HH MENU programs of the control unit ( ADIC), H3, Channel 1, select YES to enable the component. NOTE: To enter the HH MENU programs, refer to dedicated chapter in this manual.

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6020-FWD (four wheel drive) command switch fault Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation Cause: Both AUTO and MANUAL signal X-230 pin 1 and 24 shorted to power for more than 3 s Possible failure modes: 1. Faulty connector 2. 4WD switch faulty 3. wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the 4WD switch connector X-374 and the connector of the control unit ( CCU) X-230 A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. check for a short to positive voltage A. Disconnect the 4WD switch connector X-374 and connector of the central control unit X-230 turn the key ON and check between: X-374 pin 1, wire 0.5 (TQ/GN) and ground X-374 pin 3, wire 0.5 (TQ) and ground X-230 pin 1 wire 0.5 (TQ) and ground X-230 pin 24 wire 0.5 (TQ/GN) and groundIf a positive voltage is indicated repair or replace as required B. If a voltage is not indicated continue to 3 3. Check for a short circuit A. Check between: X-230 pin 1, wire 0.5 (TQ) and X-230 pin 24 wire 0.5 (TQ/GN) If a short circuit is indicated, repair or replace the harness as required B. If short circuit is not indicated, continue to 4 4. Check for faulty switch A. Turn the ignition key switch OFF, replace the 4WD switch, connect the connectors X-374 to the switch and X-230 to the central control unit ( CCU) clear the fault code in H8 menu, turn the ignition key switch ON and check the 4WD switch functionality. If the error is not present, check the system for normal operation B. If the error is still present, download the correct level of software. If the error is repeated, remove and replace the control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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6023-FWD solenoid short to ground or open circuit Control Module : CCU Cause: Short to ground or open circuit between the four-wheel drive clutch solenoid valve and the central control unit ( CCU), or the solenoid valve is faulty. Possible failure modes: 1. Faulty connectors 2. Four-wheel drive clutch solenoid valve faulty 3. Wiring fault 4. Central control unit ( CCU) trouble Solution: 1. Check the four-wheel drive clutch solenoid valve connector X-342 , the transmission - cab main connector X-300, and the connector of the control unit ( CCU) X-240. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the four wheel drive clutch solenoid. A. Disconnect the connector X-342. Measure the resistance in the connector on the component side: X-342 between pins 1 and 2 If the resistance indicated is not approximately 7.0 - 7.6 ÎŠ, remove and replace the four-wheel drive solenoid valve. B. If the resistance is okay, continue to step 3 3. Check the four-wheel drive solenoid valve for short to ground. A. Check between the component side of connector: X-342 pin 1 and ground X-342 pin 2 and ground If a short to ground is indicated, remove and replace the solenoid. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to ground. A. Disconnect the connector X-240. Check between: X-240 pin 17, wire 1.0 (BL/GN) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for an open circuit. A. Check between: X-342 pin 1, wire 1.0 (BL/GN) and X-240 pin 17, wire 1.0 (BL/GN) X-342 pin 2, wire 1.0 (BK) and ground If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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7014-Differential lock command switch error - switch disconnected Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation Possible failure modes: 1. Faulty connector 2. Wiring fault 3. Differential lock switch faulty 4. Central control unit ( CCU) fault Solution: 1. Check the differential lock switch connector X-375 and the connector of the central control unit ( CCU) X-240 A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check for a voltage of approximately 12 V A. Disconnect the differential lock switch connector X-375 turn the ignition key switch in ON position and check on the connector side between: X-375 pin 2, wire 0.5 (GY/BL) and ground X-375 pin 5, wire 0.5 (GY/BL) and ground If a positive voltage approximately of 12 V is not indicated repair or replace as required B. If a voltage approximately of 12 V is indicatedcontinue to 3 3. Check for an open circuit A. Turn the starting key in OFF position, disconnect the connector of the central control unit X-240, check continuity between: X-375 pin 1, wire 0.5 (RD/GN) and X-240 pin 30, wire 0.5 (RD/GN) X-375 pin 6, wire 0.5 (RD/YE) and X-240 pin 31, wire 0.5 (RD/YE) If an open circuit is indicated repair or replace the wire as required B. If continuity is correctly indicated, continue to step 4 4. Check for a short to ground A. Check between: X-375 pin 1 and ground X-375 pin 6 and ground If a short to ground is indicatedrepair or replace the wire as required B. If a short to ground is not indicatedcontinue to step 5 5. Change the differential lock switch S-011, of the connector ( X-375). A. Change the differential lock switch and test the system for correct operation. If the error is still present, download the correct level of software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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7017-Differential lock short to ground or open circuit Control Module : CCU Cause: Short to ground or open circuit between the differential lock solenoid valve and the central control unit ( CCU), or the solenoid valve is faulty. Possible failure modes: 1. Faulty connectors 2. Differential lock solenoid valve faulty 3. Wiring fault 4. Control unit ( CCU) fault Solution: 1. Check the differential lock solenoid valve connector X-343 , the transmission - cab main connector X-300, and the connector of the control unit ( CCU) X-240. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the solenoid valve of the differential lock. A. Disconnect the connector X-343. Measure the resistance in the connector on the component side: X-343 between pins 1 and 2 If the resistance indicated is not approximately 7.0 - 7.6 ÎŠ at 20 Â°C (68.0 Â°F) , remove and replace the solenoid valve. B. If the resistance is okay, continue to step 3 3. Check the differential lock solenoid for a short to ground. A. Check between the component side of connector: X-343 pin 1 and ground X-343 pin 2 and ground If a short to ground is indicated, remove and replace the solenoid. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to ground. A. Disconnect the connector X-240. Check between: X-343 pin 1, wire 1.0 (YE) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for an open circuit. A. Check between: X-343 pin 1, wire 1.0 (YE) and X-240 pin 9, wire 0.5 (YE) X-343 pin 2, wire 1.0 (BK) and ground If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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8008-Front PTO solenoid - open circuit or short to VBat Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation Cause: Short to ground or open circuit between the front PTO solenoid and the central control unit ( CCU), or the solenoid valve is faulty. Possible failure modes: 1. Faulty connectors 2. Front PTO solenoid faulty 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the front PTO solenoid connector X-346, the inline harness connector X-001 , the connector of the central control unit ( CCU) X-200 and the connector of the central control unit ( CCU) X-220. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the front PTO solenoid. A. Disconnect the connector X-346. Measure the resistance between the component side of connector: X-346 between pins 1 and 2 If the resistance indicated is not approximately 10 Ω at 20 °C (68.0 °F) , remove and replace the front PTO solenoid. B. If the resistance is okay, continue to step 3 3. Check the front PTO solenoid valve for a short to ground. A. Check between the component side of connector: X-346 pin 1 and ground X-346 pin 2 and ground If a short to ground is indicated, remove and replace the solenoid valve. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to ground. A. Disconnect the connectors X-200 and X-220 . Check between: X-346 pin 1, wire 1.0 (YE/BK) and ground X-346 pin 2, wire 1.0 (YE/RD) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to 5 5. Check for an open circuit. A. Check between: X-346 pin 1, wire 1.0 (YE/BK) and X-220 pin 7, wire 0.5 (YE/BK) X-346 pin 2, wire 1.0 (YE/RD) and X-200 pin 13, wire 0.5 (YE/RD) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, go to 6 47538922 29/05/2013

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6. Check for a short to + 12 V A. Turn the ignition key switch ON and check between: X-346 pin 1, wire 1.0 (YE/BK) and ground X-346 pin 2, wire 1.0 (YE/BK) and ground If voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU)

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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8033-Front PTO cab normally closed switch - open circuit Control Module : CCU Context: Effects: Front PTO disabled. Possible failure modes: 1. Faulty connectors 2. Faulty front PTO switch 3. Wiring fault 4. Central control unit ( CCU) fault Solution: 1. Check the front PTO cab switch connector X-348, the connector of the central control unit ( CCU) X-230 and the connector of the central control unit ( CCU) X-240. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 2 2. Check the front PTO cab switch. A. Disconnect the front PTO cab switch connector X-348. Operating the switch, check between: X-348 pin 1 and X-348 pin 3 The indication must be: approximately 3900 Ω when disengaged; an open circuit when engaged and an open circuit when only the yellow button is pressed. X-348 pin 1 and X-348 pin 2 The indication must be: an open circuit when disengaged; approximately 3900 Ω when engaged and an open circuit when only the yellow button is pressed. X-348 pin 2 and X-348 pin 3 An open circuit must be indicated when disengaged, engaged or when only the yellow button is pressed. If the switch operation is not as indicated, remove and replace the front PTO switch. B. If the switch is okay, continue to step 3 3. Check for a short to + 12 V. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-348 pin 1, wire 0.5 (GY/BL) and ground If the indicated voltage is not + 12 V, repair or replace the harness as required. B. If + 12 V is indicated, continue to step 4 4. Check for an open circuit. A. Turn ignition key switch to OFF position. Disconnect the connector of the central control unit ( CCU) X-230. Check between the connector: X-348 pin 3, wire 0.5 (WH) and X-230 pin 22, wire 0.5 (WH) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for a short to ground. A. Check between the connector: X-230 pin 22, wire 0.5 (WH) and ground If a short to ground is indicated, repair or replace the harness as required.

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B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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8037-Front PTO cab normally open switch - stuck closed Control Module : CCU Context: Effects: Front PTO disabled. Possible failure modes: 1. Faulty front PTO switch 2. Wiring fault 3. Central control unit ( CCU) fault Solution: 1. Check the front PTO cab switch. A. Disconnect the front PTO cab switch connector X-348. Operating the switch, check between: X-348 pin 1 and X-348 pin 3 The indication must be: approximately 3900 Ω when disengaged; an open circuit when engaged and an open circuit when only the yellow button is pressed. X-348 pin 1 and X-348 pin 2 The indication must be: an open circuit when disengaged; approximately 3900 Ω when engaged and an open circuit when only the yellow button is pressed. X-348 pin 2 and X-348 pin 3 An open circuit must be indicated when disengaged, engaged or when only the yellow button is pressed. If the switch operation is not as indicated, remove and replace the PTO switch. B. If the switch is okay, continue with step 2 2. Check for a short circuit. A. Disconnect the connectors of the central control unit ( CCU) X-240 and X-230. Check between the connector: X-348 pin 3, wire 0.5 (WH) and X-348 pin 2, wire 0.5 (WH) If a short circuit is indicated, repair or replace the harness as required. B. If a short circuit is not indicated, continue to step 3 3. Check for short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-348 pin 2, wire 0.5 (WH) and ground If voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the central control unit ( CCU).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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8099-Front PTO option not enabled Control Module : CCU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: The front PTO option has not been enabled. Possible failure modes: 1. Front PTO option has not been enabled. Solution: 1. Check the front PTO option has been enabled. A. Using the H3 options menu, set the front PTO option to 'YES'.

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3001-Foot throttle position sensor - signal not plausible Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty connector 2. Faulty foot throttle pedal 3. Faulty harness 4. Faulty controller Solution: 1. Check the foot throttle pedal potentiometer in H9 Channel 8. A. Operate the foot throttle pedal. If the values displayed do not change continuously between 250 - 4500 mV , continue to step 2 B. If the values displayed are okay, while in H9 Channel 8, wiggle the harness, the foot throttle connector X-321 and the controller connectors X-450 and X-460 to check for an intermittent circuit. Channel 8 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the foot throttle connector X-321 and the controller connectors X-450 and X-460. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for 5 Volts. A. Disconnect connector X-321. Turn the ignition key switch ON. Measure the voltage between connector: X-321 pin 4, wire 11 (TQ) and ground X-321 pin 3, wire 184 (OR) and ground If the voltage indicated is not approximately 5 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately 5 Volts, continue to step 4 4. Check for an open circuit ground circuit. A. Turn the ignition key switch OFF. Check between connector: X-321 pin 7, wire 88 (BK) and ground X-321 pin 8, wire 75 (BK) and ground If an open circuit is indicated, repair or replace the harness as required B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Disconnect the controller connectors X-450 and X-460. Check between connectors X-321 pin 2, wire 34 (WH/BK) and X-450 pin 5, wire 34 (WH/BK) X-321 pin 6, wire 225 (WH) and X-450 pin 7, ,wire 225 (WH) If an open circuit is indicated, repair or replace the harness as required B. If an open circuit is not indicated, continue to step 6 6. Check for a short to ground. A. Check between connector: 47538922 29/05/2013

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X-321 pin 2, wire 34 (WH/BK) and ground X-321 pin 6, wire 225 (WH) and ground If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 7 7. Check for a short to Ve Voltage. A. Turn the ignition key switch ON. Measure the voltage between connector: X-321 pin 2, wire 34 (WH/BK) and ground X-321 pin 6, wire 225 (WH) and ground If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 8 8. Check for a short circuit. A. Turn the ignition key switch OFF. Check between connector X-321 pin 2, wire 34 (WH/BK) and X-321 pin 6, wire 225 (WH) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the foot throttle pedal, If the fault is still present, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16) Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3002-Foot throttle position sensor - signal too high Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty connector 2. Faulty foot throttle pedal sensor 3. Faulty harness 4. Faulty controller Solution: 1. Check the foot throttle pedal potentiometer in H9 Channel 8. A. Operate the foot throttle pedal. If the values displayed do not change continuously between 250 - 4500 mV, continue to step 2 B. If the values displayed are okay, while in H9 Channel 8, wiggle the harness, the foot throttle connector X-321 and the controller connectors X-450 and X-460 to check for an intermittent circuit. Channel 8 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the foot throttle connector X-321 and the controller connectors X-450 and X-460. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for 5 Volts. A. Disconnect connector X-321. Turn the ignition key switch ON. Measure the voltage between connector X-321 pin 4, wire 11 (TQ) and ground. If the voltage indicated is not approximately 5 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately 5 Volts, continue to step 4 4. Check for an open circuit ground circuit. A. Turn the ignition key switch OFF. Check between connector X-321 pin 8, wire 75 (BK) and ground. If an open circuit is indicated, repair or replace the harness as required B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Disconnect the controller connector X-450. Check between connector X-450 pin 5 (WH/BK) and X-321 pin 2, wire 34 (WH/BK). If an open circuit is indicated, repair or replace the harness as required B. If an open circuit is not indicated, continue to step 6 6. Check for a short to Ve Voltage. A. Turn the ignition key switch ON. Measure the voltage between connector X-321 pin 2, wire 34 (WH/BK) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the foot throttle pedal, If the fault is still present, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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3003-Foot throttle position sensor - signal too low Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty connector 2. Faulty foot throttle pedal sensor 3. Faulty harness 4. Faulty controller Solution: 1. Check the foot throttle pedal potentiometer in H9 Channel 8. A. Operate the foot throttle pedal. If the values displayed do not change continuously between 250 - 4500 mV , continue to step 2 B. If the values displayed are okay, while in H9 Channel 8, wiggle the harness, the foot throttle connector X-321 and the controller connectors X-450 and X-460 to check for an intermittent circuit. Channel 8 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the foot throttle connector X-321 and the controller connectors X-450 and X-460. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for 5 Volts. A. Disconnect connector X-321. Turn the ignition key switch ON. Measure the voltage between connector X-321 pin 4, wire 11(TQ) and ground. If the voltage indicated is not approximately 5 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately 5 Volts, continue to step 4 4. Check for an open circuit ground circuit. A. Turn the ignition key switch OFF. Check between connector X-321 pin 8, wire 75 (BK) and ground. If an open circuit is indicated, repair or replace the harness as required B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Disconnect the controller connector X-450. Check between connector X-450 pin 5 (WH/BK) and X-321 pin 2, wire 34 (WH/BK). If an open circuit is indicated, repair or replace the harness as required B. If an open circuit is not indicated, continue to step 6 6. Check for a short to ground. A. Check between connector X-321 pin 2, wire 34 (WH/BK) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the foot throttle pedal, If the fault is still present, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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3007-Engine coolant temperature sensor - signal too high Control Module : ECU Context: The Engine Control Unit (ECU) generated an error from a fault associated with the coolant temperature sensor. This error could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines that the Coolant temperature sensor temperature value is not valid, it will substitute another value to be used. In case of a defective coolant temperature sensor during engine warm-up, a default coolant temperature value is derived from the ramp of the currently logged sensor data. If an error would occur during normal engine operation, the oil temperature is used as the default value. If the oil temperature / pressure sensor is defective, 89.96 Â°C (193.9 Â°F) is substituted as the default value. Cause: The coolant temperature sensor signal to the ECU is out of range of the upper threshold limit. Possible failure modes: 1. Faulty electrical wiring, short to high source or open circuit condition. 2. Faulty coolant temperature sensor. 3. Faulty ECU. Solution: 1. Verify the fault code is present and active. A. If fault code is present and active, continue with 2. B. If fault code is no longer present, continue with step 6. 2. Verify complete voltage supply circuit for the coolant temperature sensor. Disconnect the connector X-969 from coolant temperature sensor and check for voltage outlined in the table below. Test Type 1. Voltage

From Coolant temperature sensor connector X-969 pin 1 (+)

To Expected Results Coolant temperature sen- Approximately. 5 volts sor connector X-969 pin 2 (-)

A. If 5 volts is present, continue with step 4. B. If 5 volts is not present, continue with step 3. 3. Check for faulty wiring. Disconnect and perform continuity tests between the coolant temperature sensor connector X-969 and the ECU engine connector X-939 on the engine sensor harness. Flex harness during test to check for any intermittent operation. See test table below.

Test Type 1. Continuity

2. Continuity

3. Short Circuit

From To Coolant temperature sen- ECU engine sor connector X-969 pin 1 X-939 pin 57, (GY/RD) Coolant temperature sen- ECU engine sor connector X-969 pin 2 X-939, pin 58, (GY/TQ) ECU engine connector ECU engine X-939 pin 57, wire 421 X-939 pin 58, (GY/TQ) (GY/RD)

A. If continuity/short tests are successful, continue with step 4.

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Expected Results connector Approx. 0 - 0.10 ohms wire 421 connector Approx. 0 - 0.10 ohms wire 422 connector Open Circuit wire 422

Electrical systems - FAULT CODES

B. If continuity/short test are unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Verify proper coolant temperature sensor operation. Disconnect the coolant temperature sensor connector X-969 and test resistance of coolant temperature sensor using the table of resistance vs temperature below. Approximate the temperature when performing test. Coolant temperature sensor failures are typically at the extreme ends of the table or off the table entirely. Resistance Value 10.5 kOhm 7500 ohms 4200 ohms 980 ohms 780 ohms 500 ohms 280 ohms 97 ohms

Coolant Temperature -20 °C (-4 °F) 0 °C (32 °F) 20 °C (68 °F) 40 °C (104 °F) 60 °C (140 °F) 80 °C (176 °F) 100 °C (212 °F) 120 °C (248 °F)

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, continue with step 5. 5. Verify ECU ground and voltage supply. Use the product schematic for a reference, with the key switch OFF disconnect ECU vehicle connector X-937 from the ECU. Check for 12 volts with the key switch in the ON position, and continuity at the appropriate pins defined in the test table below. Test Type 1. Voltage 2. Continuity

From ECU vehicle X-937 (Pin 1, 3, ECU vehicle X-937 (Pin 2, 4,

To connector Ground (engine block) 5) connector Ground (engine block) 6)

Expected Results Approximately. 12 volts Approx. 0 - 0.10 ohms

A. If the voltages and ground paths are correct and the ECU was re-initialized on a prior diagnostic of this type, replace the ECU. B. If the voltages and ground paths are not correct locate and repair the damaged section(s) of the wiring harness. 6. Visually inspect the relevant harnesses and connectors X-969 and X-939 for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the Display. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or other than normal display readings are indicated, erase the fault code and continue operation.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3008-Engine coolant temperature sensor - signal too low Control Module : ECU Context: The Engine Control Unit (ECU) generated an error from a fault associated with the coolant temperature sensor. This error could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines that the coolant temperature sensor temperature value is not valid, it will substitute another value to be used. In case of a defective Coolant temperature sensor during engine warm-up, a default coolant temperature value is derived from the ramp of the currently logged sensor data. If an error would occur during normal engine operation, the oil temperature is used as the default value. If the oil temperature / pressure sensor is defective, 89.96 °C (193.9 °F) is substituted as the default value. Cause: The coolant temperature sensor signal to the ECU is out of range of the lower threshold limit. Possible failure modes: 1. Faulty electrical wiring, short to low source condition. 2. Faulty Coolant temperature sensor. 3. Faulty ECU. Solution: 1. Verify the fault code is present and active. A. If fault code is present and active, continue with step 3. B. If fault code is no longer present, continue with step 6. 2. Verify Coolant temperature sensor is working properly. Disconnect the Coolant temperature sensor connector X-969, and test resistance of the coolant temperature sensor using the table of resistance vs temperature below. Resistance Value 10.5 kOhm 7500 ohms 4200 ohms 980 ohms 780 ohms 500 ohms 280 ohms 97 ohms

Coolant Temperature -20 °C (-4 °F) 0 °C (32 °F) 20 °C (68 °F) 40 °C (104 °F) 60 °C (140 °F) 80 °C (176 °F) 100 °C (212 °F) 120 °C (248 °F)

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, continue with step 4. 3. Check for supply voltage from the ECU in the coolant temperature sensor supply wiring. Disconnect the connector from coolant temperature sensor X-969 and check for voltage between coolant temperature sensor connector X-969 pin 1 and ground. There should be 5 volts. A. If 5 volts is present, continue with step 5. B. If 5 volts is not present, continue with step 2. 4. Check the ECU output to the coolant temperature sensor. With the ignition key switch in the OFF position, disconnect the coolant temperature sensor connector X-969 and the ECU engine connector X-939 on engine sensor harness. Turn the ignition key switch to the ON position and check for voltage between ECU engine connector X-939 pin 57, wire 421 (GY/RD) and ground. There should be 5 volts.

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A. If 5 volts is present, locate a repair the open circuit condition between the ECU engine connector X-939 pin 57, wire 421 (GY/RD) and the coolant temperature sensor connector X-969 pin 1. B. If 5 volts is not present, replace the ECU. 5. Verify the coolant temperature sensor ground path. With the ignition key switch in the OFF position, disconnect ECU engine connector X-939, and check for continuity to ground from connector X-939 pin 58, wire 422 (GY/TQ) of the ECU. A. If there is continuity, locate and repair short to ground in Engine sensor harness between the ECU engine connector X-939 and the coolant temperature sensor connector X-969. B. If there is not continuity, replace the ECU. 6. Visually inspect the relevant harnesses and connectors X-969 and X-939 for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the Display. A. If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. B. If no damage or no other than normal display readings are indicated, erase the fault code and continue operation.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3010-Intake air pressure and temperature sensor - temperature signal too high Control Module : ECU Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The Boost Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to the temperature sensing function of the device. This error could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines that the Boost Pressure sensor value is not valid, it will substitute a default value of 29.96 Â°C (86 Â°F). Cause: The Boost Pressure sensor signal to the ECU is out of range of the upper threshold limit. Possible failure modes: 1. Faulty sensor. 2. Faulty electrical wiring or connection. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Check electrical connections and wiring. Remove Boost Pressure sensor connector X-961 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the Boost Pressure sensor. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace Boost Pressure sensor if damaged. B. If no damage is determined, proceed to step 2. 2. Check Open Circuit Voltages for Boost Pressure sensor. Place the ignition switch OFF. Remove connector X-961 from Boost Pressure sensor and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type 1. Voltage 2. Voltage 3. Voltage

From X-961 pin 3 X-961 pin 2 X-961 pin 4

To X-961 pin 1 X-961 pin 1 X-961 pin 1

Expected Results Approx. 5 volts Approx. 5 volts Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3. 3. Check for Faulty Wiring. Place the ignition switch OFF. Remove and perform continuity/shorts tests between connectors X-961 and X-939 on engine wiring harness. Flex harness during test to check for any intermittent operation. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X-961. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multi-meter (DMM) to connector X-939. Make sure the DMM's test lead resistance is taken into account when making continuity measurements. See test table below. Important Note: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed.

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Test Type 1. Continuity 2. Continuity 3. Continuity 4. Continuity 5. Shorts

6. Shorts

7. Shorts

From: X-961 pin 1

To: X-939 pin 25, wire 403 (OR) X-961 pin 2 X-939 pin 55, wire 420 (GY/ GN) X-961 pin 3 X-939 pin 10, wire 395 (GN/BK) X-961 pin 4 X-939 pin 40, wire 412 (RD/ BK) X-939 pin 55, wire 420 (GY/ X-939 pin 25, wire 403 (OR), pin 10, wire 395 (GN/ GN) BK), pin 40, wire 412 (RD/ BK) X-939 pin 25 X-939 pin 10, wire 395 (GN/BK), pin 40, wire 412 (RD/BK) X-939 pin 40 X-939 pin 10, wire 395 (GN/BK)

Expected Results Approx. 0 - 0.10 ohms Approx. 0 - 0.10 ohms Approx. 0 - 0.10 ohms Approx. 0 - 0.10 ohms Open Circuit

Open Circuit

A. If continuity/shorts test is successful, go to step 5. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Check Boost pressure sensor for proper operation. Place the ignition switch OFF. Remove the Boost Pressure sensor connector X-939 and remove the sensor from the engine intake manifold. Allow the sensor to cool to ambient temperature for several minutes, and then test sensor resistance across pins 2 and 3, using the table of resistance vs. temperature below. Approximate the ambient air temperature when performing the test. Boost Pressure sensor failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the contacts on the Boost Pressure sensor (pins 2 and 3). Temperature -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) 35 °C (95 °F) 40 °C (104 °F) 45 °C (113 °F) 50 °C (122 °F) 55 °C (131 °F) 60 °C (140 °F) 65 °C (149 °F) 70 °C (158 °F) 75 °C (167 °F) 80 °C (176 °F) 85 °C (185 °F) 90 °C (194 °F)

Resistance Nominal Value 48153 ohms 35763 ohms 26854 ohms 20376 ohms 15614 ohms 12078 ohms 9426 ohms 7419 ohms 5887 ohms 4707 ohms 3791 ohms 3075 ohms 2511 ohms 2063 ohms 1715 ohms 1432 ohms 1199 ohms 1009 ohms 851 ohms 721 ohms 612 ohms 522 ohms 446 ohms 383 ohms 329 ohms 284 ohms 246 ohms 47538922 29/05/2013

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Resistance Min/Max. Range 45301 - 51006 ohms 33703 - 37823 ohms 25350 - 28359 ohms 19265 - 21487 ohms 14785 - 16443 ohms 11453 - 12702 ohms 8951 - 9901 ohms 7055 - 7783 ohms 5605 - 6168 ohms 4487 - 4926 ohms 3618 - 3964 ohms 2939 - 3211 ohms 2402 - 2619 ohms 1976 - 2150 ohms 1645 - 1786 ohms 1374 - 1490 ohms 1152 - 1247 ohms 970 - 1047 ohms 819 - 883 ohms 694 - 747 ohms 590 - 634 ohms 503 - 540 ohms 431 - 462 ohms 370 - 396 ohms 319 - 340 ohms 275 - 293 ohms 238 - 254 ohms

Electrical systems - FAULT CODES

Temperature 95 °C (203 °F) 100 °C (212 °F) 105 °C (221 °F) 110 °C (230 °F) 115 °C (239 °F) 120 °C (248 °F) 125 °C (257 °F) 130 °C (266 °F)

Resistance Nominal Value 214 ohms 186 ohms 162 ohms 142 ohms 125 ohms 110 ohms 97 ohms 85 ohms

Resistance Min/Max. Range 207 - 220 ohms 180 - 192 ohms 157 - 167 ohms 138 - 147 ohms 121 - 129 ohms 106 - 113 ohms 93 - 100 ohms 83 - 88 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 5. 5. Check for ECU Voltages and Ground Continuity. Use product schematic. Place the ignition switch OFF. Remove connector X-937 from the ECU. Place the ignition switch ON to check for voltage at the appropriate pins defined in the test table below. Place the ignition switch OFF to check for continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to connector X-939. Make sure the DMM's test lead resistance is taken into account when making any continuity measurements. Important Note: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type 1. Voltage

2. Continuity

From To X-937 pin 1 (RD/BK), pin Ground (engine block) 3 (RD/YE), pin 5 (RD/YE), pin 29 wire 341 (OR) X-937 pin 2 (BK), pin 4 Ground (engine block) (BK), pin 6 (BK)

Expected Results Approx. 12 volts

Approx. 0 - 0.10 ohms

A. If the voltages and ground paths are correct and the Boost Pressure sensor was not replaced on a prior diagnostic of this type, replace the sensor. B. If the voltages and ground paths are correct and the Boost Pressure sensor was replaced on a prior diagnostic of this type, re-initialize the ECU as if it was blank (new) and load the appropriate data-set. C. If the voltages and ground paths are correct and the ECU was re-initialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to schematic and determine root cause of power or continuity problem(s).

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18) Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3011-Intake air pressure and temperature sensor - temperature signal too low Control Module : ECU Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The Boost Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to the temperature sensing function of the device. This error could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines that the Boost Pressure sensor value is not valid, it will substitute a default value of 29.96 Â°C (86 Â°F). Cause: The Boost Pressure sensor signal to the ECU is out of range of the lower threshold limit. Possible failure modes: 1. Faulty sensor. 2. Faulty electrical wiring or connection. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Check electrical connections and wiring. Place the ignition switch OFF. Remove Boost Pressure sensor connector X-961 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the Boost Pressure sensor. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace Boost Pressure sensor if damaged. B. If no damage is determined, proceed to step 2. 2. Check Open Circuit Voltages for Boost Pressure sensor. Place the ignition switch OFF. Remove X-961 connector from Boost Pressure sensor and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type 1. Voltage 2. Voltage 3. Voltage

From X-961 pin 3 X-961 pin 2 X-961 pin 4

To X-961 pin 1 X-961 pin 1 X-961 pin 1

Expected Results Approx. 5 volts Approx. 5 volts Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3. 3. Check for Faulty Wiring. Place the ignition switch OFF. Remove and perform continuity/shorts tests between connectors X-961 and X-939 on engine wiring harness. Flex harness during test to check for any intermittent operation. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X-961. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multi-meter (DMM) to the X-939 connector. Make sure the DMM's test lead resistance is taken into account when making continuity measurements. See test table below. Important Note: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed.

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Test Type 1. Continuity 2. Continuity 3. Continuity 4. Continuity 5. Shorts

6. Shorts

7. Shorts

From: X-961 pin 1

Expected Results Approx. 0 - 0.10 ohms Approx. 0 - 0.10 ohms Approx. 0 - 0.10 ohms Approx. 0 - 0.10 ohms Open Circuit

Open Circuit

A. If continuity/shorts test is successful, go to step 5. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Check Boost pressure sensor for proper operation. Place the ignition switch OFF. Remove the Boost Pressure sensor connector X-961 and remove the sensor from the engine intake manifold. Allow the sensor to cool to ambient temperature for several minutes, and then test sensor resistance across pins 2 and 3, using the table of resistance vs. temperature below. Approximate the ambient air temperature when performing the test. Boost Pressure sensor failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the contacts on the Boost Pressure sensor (pins 2 and 3). Temperature -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) 35 °C (95 °F) 40 °C (104 °F) 45 °C (113 °F) 50 °C (122 °F) 55 °C (131 °F) 60 °C (140 °F) 65 °C (149 °F) 70 °C (158 °F) 75 °C (167 °F) 80 °C (176 °F) 85 °C (185 °F) 90 °C (194 °F)

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Temperature 95 °C (203 °F) 100 °C (212 °F) 105 °C (221 °F) 110 °C (230 °F) 115 °C (239 °F) 120 °C (248 °F) 125 °C (257 °F) 130 °C (266 °F)

Resistance Nominal Value 214 ohms 186 ohms 162 ohms 142 ohms 125 ohms 110 ohms 97 ohms 85 ohms

Resistance Min/Max. Range 207 - 220 ohms 180 - 192 ohms 157 - 167 ohms 138 - 147 ohms 121 - 129 ohms 106 - 113 ohms 93 - 100 ohms 83 - 88 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 5. 5. Check for ECU Voltages and Ground Continuity. Use product schematic. Place the ignition switch OFF. Remove connector X-937 from the ECU. Place the ignition switch ON to check for voltage at the appropriate pins defined in the test table below. Place the ignition switch OFF to check for continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to connector X-937. Make sure the DMM's test lead resistance is taken into account when making any continuity measurements. Important Note: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type 1. Voltage

2. Continuity

From To X-937 pin 1 (RD/BK), pin Ground (engine block) 3 (RD/YE), pin 5 (RD/YE), pin 54 (OR) X-937 pin 2 (BK), pin 4 Ground (engine block) (BK), pin 6 (BK)

Expected Results Approx. 12 volts

Approx. 0 - 0.10 ohms

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18) Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3015-Fuel temperature sensor - signal too high Control Module : ECU Context: The Engine Control Unit (ECU) has detected a fault associated with Fuel temperature sensor. This error typically results from a signal that is out of range. When the ECU determines that the Fuel temperature sensor temperature value is invalid, it will substitute the current coolant temperature value, or in the case of a defective Coolant temperature sensor , the value 19.96 ° C (67.9 °F) will be substituted. Cause: The Fuel temperature sensor signal to the ECU is out of the range of the upper threshold limit. Possible failure modes: 1. Faulty Fuel temperature sensor. 2. Faulty electrical wiring or short to high source or open circuit condition. 3. Faulty ECU.. Solution: 1. Verify the fault code is still present and in an active state. 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, return machine to proper operation. 2. Check electrical connections and wiring. Check the connections and wiring from the fuel temperature sensor to the ECU are secure and tight. Ensure all pins are clean and in good condition. A. If any connectors, wiring or pins are damaged, loose or corroded. Repair or replace as required. B. If all connections, wiring and pins are in good condition, continue with step 3. 3. Ensure electrical integrity of the Fuel temperature sensor. Remove connector X-968 from the Fuel temperature sensor and use a multi-meter to check the resistance of the sensor. Use the table below to ensure proper sensor resistance. Fuel Temperature -20 °C (-4 °F) 0 °C (32 °F) 20 °C (68 °F) 40 °C (104 °F) 60 °C (140 °F) 80 °C (176 °F) 100 °C (212 °F) 120 °C (248 °F)

Resistance Value 10.5 kOhm 7500 ohms 4200 ohms 980 ohms 780 ohms 500 ohms 280 ohms 97 ohms

A. If sensor resistance is within range leave connector X-968 disconnected and continue with step 4. B. If the sensor is out of range, replace the sensor. 4. Verify proper supply voltage to the sensor. Measure voltage between connector X-968 pin 1 to ground. There should be 5 V. A. If there is 5 V, download the latest software. If fault re-occurs, replace ECU. B. If there is greater than 5 V, repair or replace harness as required.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3016-Fuel temperature sensor - signal too low Control Module : ECU Context: The Engine Control Unit (ECU) has generated a fault associated with Fuel temperature sensor . This error typically results from a signal that is out of range. When the ECU determines that the fuel temperature sensor temperature value is invalid, it will substitute the current "Coolant Temperature" value, or in the case of a defective Coolant temperature sensor , the value 19.96 Â°C (67.9 Â°F) will be substituted. Cause: The Fuel temperature sensor signal to the ECU is out of the range of the lower threshold limit. Possible failure modes: 1. Faulty Fuel temperature sensor . 2. Faulty electrical wiring or short to low source (ground). 3. Faulty ECU, supply voltages or grounds. Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Check electrical connections and wiring. Place the ignition switch OFF. Remove Fuel temp sensor connector X-968 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the Fuel temp sensor. A. If a problem is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace Fuel temp sensor if damaged. B. If no problems are determined, proceed to step 3. 3. Check Supply Voltage for Fuel temp sensor. Place the ignition switch OFF. Use the test lead labeled "Coolant/ Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Remove connector from Fuel temp sensor and check for voltage from X-968 pin 1 to X-968 pin 2. There should be approximately 5 volts. A. If the voltage test is successful, proceed to step 5. B. If the voltage test is not successful, proceed to step 4. 4. Check faulty wiring. Place the ignition switch OFF. Remove and perform continuity tests between connector X-968 and connector X-939 on engine sensor harness. Flex harness during test to check for any intermittent operation. Use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X-968. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multi-meter (DMM) to connector X-939. Make sure the DMM's test lead resistance is taken into account when taking continuity measurements. See test table below. Important Note: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type 1. Continuity

From X-968 pin 1

2. Continuity

X-968 pin 2

To Expected Results X-939 pin 38, wire 410 (TQ/ Approx. 0 - 0.10 ohms WH) X-939 pin 23, wire 401(BR/ Approx. 0 - 0.10 ohms WH)

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3. Short Circuit

X-939 pin 38, wire 410 X-939 pin 23, wire 401(BR/ Open Circuit (TQ/W) WH)

A. If continuity/shorts test is successful, go to step 5. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 5. Operation: Fuel temp sensor Test Vehicle Status: Key Off Engine Off. Remove Fuel temp sensor connector X-968 and test resistance of Fuel temp sensor using the table of resistance vs. temp. below. Approximate the fuel temperature when performing test. Fuel temp sensor failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor. Fuel Temperature -20 °C (-4 °F) 0 °C (32 °F) 20 °C (68 °F) 40 °C (104 °F) 60 °C (140 °F) 80 °C (176 °F) 100 °C (212 °F) 120 °C (248 °F)

Resistance Value 10.5 kOhm 7500 ohms 4200 ohms 980 ohms 780 ohms 500 ohms 280 ohms 97 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 6. 6. Check for ECU Voltages and Ground Continuity. Use product schematic. Place the ignition switch OFF. Remove connector X-937 from the ECU. Place the ignition switch ON. Check for voltage at the appropriate pins defined in the test table below. Place the ignition switch OFF. Check for continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to connector X-937. Make sure the DMM's test lead resistance is taken into account when making any continuity measurements. Important Note: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type 1. Voltage

2. Continuity

From To X-937 pin 1 (RD/BK), pin Ground (engine block) 3 (RD/YE), pin 5 (RD/YE), pin 54 (OR) X-937 pin 2 (BK), pin 4 Ground (engine block) (BK), pin 6 (BK)

Expected Results Approx. 12 volts

Approx. 0 - 0.10 ohms

A. If the voltages and ground paths are correct and the Fuel temp sensor was not replaced on a prior diagnostic of this type, replace the sensor. B. If the voltages and ground paths are correct and the Fuel temp sensor (FTS) was replaced on a prior diagnostic of this type, re-initialize the ECU as if it was blank (new) and load the appropriate data-set. C. If the voltages and ground paths are correct and the ECU was re-initialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to schematic and determine root cause of power or continuity problem(s).

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18) Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3019-Intake air pressure and temperature sensor - pressure signal too high Control Module : ECU Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The Boost Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to the pressure sensing function of the device. This error could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines that the Boost Pressure sensor value is not valid, it will substitute a default value of 270 kPa (39 psi). Cause: The Boost Pressure sensor signal to the ECU is out of range of the upper threshold limit. Possible failure modes: 1. Faulty sensor. 2. Faulty electrical wiring or connection. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Check electrical connections and wiring. Place the ignition switch OFF. Remove Boost Pressure sensor connector X-961 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the Boost Pressure sensor. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace Boost Pressure sensor if damaged. B. If no damage is determined, proceed to step 2. 2. Check Open Circuit Voltages for Boost Press sensor. Place the ignition switch OFF. Remove X-961 connector from Boost Pressure sensor and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type 1. Voltage 2. Voltage 3. Voltage

From X-961 pin 3 X-961 pin 2 X-961 pin 4

To X-961 pin 1 X-961 pin 1 X-961 pin 1

Expected Results Approx. 5 volts Approx. 5 volts Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3. 3. Check for Faulty Wiring. Place the ignition switch OFF. Remove and perform continuity/shorts tests between connectors X-961 and connector X-939 on engine wiring harness. Flex harness during test to check for any intermittent operation. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X-961. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multi-meter (DMM) to connector X-939. Make sure the DMM's test lead resistance is taken into account when making continuity measurements. See test table below. Important Note: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed.

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Test Type 1. Continuity 2. Continuity 3. Continuity 4. Continuity 5. Shorts

6. Shorts

7. Shorts

From: X-961 pin 1

Expected Results Approx. 0 - 0.10 ohms Approx. 0 - 0.10 ohms Approx. 0 - 0.10 ohms Approx. 0 - 0.10 ohms Open Circuit

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Check for ECU Voltages and Ground Continuity. Use product schematic. Place the ignition switch OFF. Remove connector X-937 from the ECU. Place the ignition switch ON to check for voltage at the appropriate pins defined in the test table below. Place the ignition switch OFF to check for continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to connector X-937. Make sure the DMM's test lead resistance is taken into account when making any continuity measurements. Important Note: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type 1. Voltage

2. Continuity

From To X-937 pin 1 (RD/BB), pin Ground (engine block) 3 (RD/YE), pin 5 (RD/YE), pin 54 (OR) X-937 pin 2 (BK), pin 4 Ground (engine block) (BK), pin 6 (BK)

Expected Results Approx. 12 volts

Approx. 0 - 0.10 ohms

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18) Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3024-Air pressure sensor - signal too high Control Module : ECU Context: The engine control unit (ECU) has detected a failure of the atmospheric pressure sensor (APS), located inside the ECU. The sensor signal level is above 4.88 V for over 800 ms. This fault will reset if the raw signal level goes below 4.88 V for over 480 ms. In the case of a defective APS the atmospheric pressure value is switched to a default value of 97 kPa (14.07 psi). If the sensor is defective the ECU should be replaced only if required. It is not necessary to replace the ECU if never running in high altitude and if engine is without variable geometry turbocharger (VGT).

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3025-Air pressure sensor - signal too low Control Module : ECU Context: The engine control unit (ECU) has detected a failure of the atmospheric pressure sensor (APS), located inside the ECU. The sensor signal level is below 190 mV. This fault will reset if the raw signal level goes above 190 mV for over 480 ms. In the case of a defective APS the atmospheric pressure value is switched to a default value of 97 kPa (14.07 psi). If the sensor is defective the ECU should be replaced only if required. It is not necessary to replace the ECU if never running in high altitude and if engine is without variable geometry turbocharger (VGT).

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3027-Engine oil pressure switch - defect fault check for plausibility Control Module : ECU Context: The engine control unit (ECU) has detected oil pressure while the engine is not running. Cause: Engine speed is less than 500 RPM and the oil pressure switch is in the closed position. The oil pressure switch will close to indicate to the ECU that the engine is running and the engine has the proper oil pressure. Possible failure modes: 1. Faulty electrical wiring, short circuit to ground in the signal wire to the ECU 2. Faulty oil press switch 3. Faulty ECU Solution: 1. Verify that the fault code is still active (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 3027 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the oil pressure switch connector X-959. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the oil pressure switch connector X-959. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. OK – The connectors are secure and the harness is free of damage. Go to Step 3. B. NOT OK – 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 through the signal wire to chassis ground (1) Turn the key switch OFF. (2) Disconnect ECU connector X-939 and the oil pressure switch connector X-959. (3). Measure the resistance between ECU connector X-939 pin 6, wire 392 (BK/WH) 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 in the signal wire to chassis ground. Repair as required. Go to Step 1 to confirm elimination of fault. 4. Measure the resistance through the oil pressure switch (1) Turn the key switch OFF. (2) Disconnect the oil pressure switch connector X-959. 47538922 29/05/2013

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(3). Measure the resistance through the switch to chassis ground. The chassis ground connection should be clean and free of oil, paint and dirt. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 10 Ω. There is a problem with the oil pressure switch. Temporarily replace the oil pressure switch and retest. Return to Step 1 to confirm elimination of fault.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3037-Boost pressure sensor - signal low Control Module : ECU NOTE: Use the test lead labeled "Air Press/Temp sensor" harness from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The Boost Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to the pressure sensing function of the device. If the sensed value of the boost pressure sensor signal is below 0.2 V. Cause: The Boost Pressure sensor circuit l to the ECU is shorted to ground or open. Possible failure modes: 1. Faulty sensor. 2. Faulty electrical wiring or connection. 3. Faulty ECU Solution: 1. Verify the fault is present. Check electrical connections and wiring. Place the ignition switch OFF. Remove boost pressure sensor connector X-961 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the boost pressure sensor. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace Boost Pressure sensor if damaged. B. If no damage is determined, leave connector X-961. Continue with step 2. 2. Check wiring harness for short to ground. Place the ignition switch OFF. Place the “Air Press/Temp sensor” labeled harness in between the boost pressure sensor and engine harness. Place the ignition switch ON. Using a multi-meter check for voltage from the engine harness side of connector X-961 pin 1 to pin 3 There should be approximately 5.0 V. A. If there is no voltage, continue with step 3. B. If there is voltage continue with step 6. 3. Check for a grounded circuit. Place the ignition switch OFF. Remove the “Air Press/Temp sensor” labeled harness. Disconnect the engine harness from the ECU at connector X-939. Use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the multi-meter to check for continuity from the engine harness side of connector X-939 pin 10, wire 395 (GN) to chassis ground. There should be no continuity. A. If there is continuity, the short to ground condition is in the engine harness between connector X-961 pin 3 and connector X-939 pin 10, wire 395 (GN). Locate and repair damaged wiring. B. If there is no continuity, leave the connectors disconnected. Continue with step 4. 4. Check for a short circuit. Place the ignition switch OFF. Use a multi-meter to check for continuity on the engine harness of connector X-961 pin 3 to pin 1. There should be no continuity. A. If there is continuity the wiring harness is shorted together. Locate and repair damaged wiring. B. If there is no continuity, continue with step 5. 5. Locate the open circuit. Place the ignition switch OFF. Use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the multi-meter to check for continuity from the engine harness side of connector X-961 pin 3 to connector X-939 pin 10, wire 395 (GN). There should be continuity.

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A. If there is no continuity, there is an open circuit in the engine harness between connector X-961 pin 3 to connector X-939 pin 10, wire 395 (GN).. Locate and repair damaged wiring. B. If there is continuity, leave connector X-939 disconnected. Continue with step 10. 6. Check the boost pressure sensor. Clear all fault codes that may be stored. Check to see if any faults are present. Fault code 3037 should be present. A. If the fault code 3037 is present, the sensor has failed. Replace the sensor. B. If the fault code is not present continue with step 7. 7. Check for short to ground condition. Place the ignition switch OFF. Disconnect the engine control harness from the ECU at connector X-939. Use a multi-meter to check for continuity from the engine harness side of connector X-961 pin 4 to chassis ground. There should be no continuity. A. If there is continuity, the short to ground condition is in the engine harness between connector X-939 pin 40, wire 412 (RD/BK) and connector X-961 pin 4. Locate and repair damaged wiring. B. If there is no continuity, continue with step 8. 8. Check for a short circuit. Place the ignition switch OFF. Use a multi-meter to check for continuity on the engine harness of connector X-961 pin 4 to pin 1. There should be no continuity. A. If there is continuity the wiring harness is shorted together. Locate and repair damaged wiring. B. If there is no continuity, continue with step 9. 9. Check for an open circuit. Place the ignition switch OFF. Use a multi-meter to check for continuity from the engine harness connector X-961 pin 4 to connector X-939 pin 40, wire 412 (RD/BK). There should be continuity. A. If there is no continuity, there is an open circuit in the engine harness between connector X-961 pin 4 to connector X-939 pin 40, wire 412 (RD/BK). Locate and repair damaged wiring. B. If there is continuity, continue with step 10. 1 Locate the open circuit. Place the ignition switch ON. Use a multi-meter to check for voltage on the ECU connector 0. X-939 pin 10, wire 395 (GN) to chassis ground. There should be approximately 5.0 V. Then check for continuity from the ECU connector X-939 pin 25,to chassis ground. There should be continuity. A. If the readings are incorrect, use wiring schematics to check that the supply voltages and grounds are present. B. If the readings are correct, try reloading the software. Recheck that the fault has cleared. If the fault has not cleared, check all connections are clean, and secure. Check for any damaged wiring, and repair as necessary.

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INT / WE markets, power shuttle transmission with Hi-Lo, with cab INT / WE markets, power shuttle transmission, with cab NA market, power shuttle transmission, with cab Power shuttle transmission, cabless Mechanical transmission, cabless INT / WE markets, mechanical transmission, with cab NA market, mechanical transmission, with cab

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3038-Constant engine speed selector switch - signals not plausible Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty constant engine speed (CRPM) selector switch (On/Off, 1/2) 4. Faulty analog digital instrument cluster ( ADIC) Solution: 1. Check the constant engine speed (CRPM) selector switch connector X-303 and the controller connector X-460. A. Ensure the connectors are connected, not damaged, the pins the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the constant engine speed (CRPM) selector switch in H5. A. Turn the ignition key switch ON. Depress the constant engine speed (CRPM) selector on/off switch, d122 should be displayed, if the display does not change to d122, continue to step 3 B. Depress the constant engine speed (CRPM) selector 1/2 switch, d123 should be displayed, if the display does not change to d123, continue to step 4 C. If the display does change to d122 and d123, while still in H5 and depressing the buttons, wiggle the harness and the constant engine speed (CRPM) selector switch connector X-303 to check for an intermittent circuit, repair or replace as required. 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connectors X-303 and X-460. Check between connector X-303 pin 3 (OR/BK) and X-460 pin 26 (OR/BK). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 4. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connectors X-303 and X-460. Check between connector X-303 pin 1 (OR/TQ) and X-460 pin 7 (OR/TQ). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for a short circuit. A. Check between connector X-303 pin 1 (OR/TQ) and X-303 pin 3 (OR/BK). If a short circuit is indicated, repair or replace the harness as required. B. If a short circuit is not indicated, continue to step 6 6. Check for 12 V. A. Turn the ignition key switch ON. Check between connector X-303 pin 2 (OR) and ground. If approximately 12 V is not indicated, repair or replace the harness as required to fuse F-020 (5 Amp). B. If the harness is okay, replace the constant engine speed (CRPM) selector switch and test the system for normal operation. If the fault occurs again, replace the analog digital instrument cluster ( ADIC). 47538922 29/05/2013

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Wire harnesses - Electrical schematic frame 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16) Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3052-ECU supply voltage - voltage too low Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: This code may be induced during cold starting. Possible failure modes: 1. Faulty battery 2. Faulty charging system 3. Faulty connector 4. Faulty harness 5. Faulty engine controller Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check the battery condition and terminal connections. A. If the battery or terminals are faulty, repair or replace as required. B. If the battery and terminals are okay, continue to step 3 3. Check the battery voltage on the instrument cluster. A. Start the engine and run at 2000 rev/min. If the voltage displayed is not between 12 - 15 V, continue to test for a fault in the charging system. B. If the battery voltage is okay, continue to step 4 4. Check the engine controller connector X-937. A. Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connector is okay, continue to step 5 5. Check the engine controller fuses F-053, F-054 and F-059. A. Ensure the fuses are not blown and that the fit is tight. Repair or replace as required. B. If the fuses are okay, continue to step 6 6. Check all power supplies and grounds to the engine controller. A. If a fault is indicated, repair or replace the harness as required. B. If no faults are indicated, download the correct level of software. If the fault reâ&#x20AC;&#x201C;occurs, remove and replace the engine controller.

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3059-Main relay ECU - stuck relay fault Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: The Main relay is controlled by the engine control unit (ECU). After key off, the ECU goes into the ‘After-run’ where storage of the failures into the memory, counting of driving cycles and the corresponding reactions occur. The main relay is controlled by the ECU to assure the After-run. The main relay is switched off by the ECU itself after the After-run has finished. After the request of ‘main relay switch off’, the ECU expects that the supply voltage drops below limit within 500 ms. If not, it is assumed that the main relay is stuck in a closed position. Possible failure modes: 1. Faulty connector 2. Faulty ECU main relay 3. Faulty harness 4. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check the ECU connector X-937 and the ECU main relay connector X-533 and the ECU main relay K–200 . A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the ECU main relay K–200. A. Remove the ECU main relay K–200 and check the operation of the relay. If the relay does not operate correctly, replace the ECU main relay K–200. B. If the relay is okay, continue to step 4 4. Check for a short circuit to ground. A. Disconnect the ECU connector X-937 and remove the ECU main relay K–200. Check between connector X-937 pin 28, wire 743 (BK/WH). If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 5 5. Check for a short circuit to battery voltage. A. Turn the ignition key switch ON. Measure the voltage between connector X-937 pin 1, wire 745 (RD/BK) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault is still present, remove and replace the ECU.

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3063-Injector cylinder 1 - short circuit Control Module : ECU NOTE: This diagnostic procedure requires a good quality multi-meter to be able to take accurate resistance measurements. The meter should be able to measure to a resolution of 0.1 ohms. Some of the measurements required to be taken, could be as low as 0.4 ohms (typical injector solenoid coil resistance is 0.4 - 0.5 ÎŠ) and any inaccuracies in the DMM could cause a technician to take the wrong diagnostic path. NOTE: Make sure that the multi-meter's test lead resistance is taken into account when resistance measurements are taken. Record the multi-meter's test lead resistance by touching the leads together on the lowest Ohms scale and mentally recording the resistance value. Subtract this value from the actual resistance measurement taken. Context: The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 1. A power stage component energizes the unit injection system transistors and simultaneously observes the current flow in the high-side and low-side switching branch by sensing resistors. If there is a deviation from the expected current flow the component detects specific errors and reports them to the ECU. This error message is then rearranged so it holds information on performed injections, errors of cylinders on the same bank, bank specific errors and cylinder specific errors. The rearranged error message is then compared to applicable error patterns and if there is a match the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of a short circuit of the high side to the low side or ground over 3 camshaft revolutions. As a result of this error an individual cylinder or bank is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent (without a healing possibility, once tested by switching on the component to see if the defect is still present). and others evoke an irreversible or reversible shut off of the engine to be executed. Cause: The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the injector output power driver stage. Possible failure modes: 1. Faulty cylinder 1 solenoid windings. 2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness). 3. Faulty ECU, ECU hardware or software. Solution: 1. Verify this fault code is still present and in an active state. 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, return machine to proper operation. 2. Carefully disconnect the engine cylinder harness from the ECU at ECU cylinder harness connector X-939. Use a multi-meter to check the resistance, on the cylinder harness side of connector X-939, between pins 16 and 32. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, leave ECU cylinder connector X-939 disconnected and continue with step 3. B. If the resistance was lower than range minimum, continue with step 6. 3. Use a multi-meter to check for continuity, on the ECU cylinder harness side of connector X-939, from pin 16 to chassis ground and pin 32 to chassis ground. There should not be continuity. A. If there was continuity on either or both pins to chassis ground, continue with step 4. B. If there was no continuity on either pin to chassis ground, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs, replace the ECU.

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4. Disconnect the engine cylinder harness from the injector (valve) cover at connector X-940. Use a multi-meter to check for continuity, on the injector (valve) cover side of connector X-940 from pin A to chassis ground and pin B to chassis ground. There should not be continuity. A. If there was continuity on either or both pins to chassis ground, leave connector X-940 disconnected and continue with step 5. B. If there was no continuity on either pin to chassis ground, there is a short to ground condition in the engine cylinder harness between Valve cover connector X-940 and ECU to cylinder harness connector X-939. Locate and repair the grounded conductor. 5. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 1 injector at connector X-951 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the injector, from terminal 1 to chassis ground. There should not be continuity. A. If there is continuity, Cylinder 1 injector's solenoid coil has failed, replace the injector. B. If there is no continuity, there is a short to ground condition in Cylinder 1 injector circuit, between connector X-951 and connector X-940. Locate and repair the grounded conductor. 6. Disconnect the engine cylinder harness from the injector (valve) cover at connector X-940 and use a multi-meter to check the resistance on the injector (valve) cover side of connector X-940 between pins A and B. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, there is a short circuit condition in the engine injector harness between the injector (valve) cover connector X-940 and ECU cylinder harness connector X-939, locate and repair the short circuit. B. If the resistance was lower than range minimum, continue with step 7. 7. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 1 injector at connector X-951 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder 1 injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, there is a short circuit condition in the injector harness, between Cylinder 1 injector connector X-951 and connector X-940. Locate and repair the shorted conductors. B. If the resistance was lower than minimum range, the Cylinder 1 injector solenoid coil has failed. Replace the injector.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3071-Injector cylinder 3 - short circuit Control Module : ECU NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to be able to take accurate resistance measurements. The meter should be able to measure to a resolution of 0.1 ohms. Some of the measurements required to be taken, could be as low as 0.4 ohms (typical injector solenoid coil resistance is 0.4 - 0.5 ÎŠ) and any inaccuracies in the DMM could cause a technician to take the wrong diagnostic path. NOTE: Make sure that the multi-meter's test lead resistance is taken into account when resistance measurements are taken. Record the multi-meter's test lead resistance by touching the leads together on the lowest Ohms scale and mentally recording the resistance value. Subtract this value from the actual resistance measurement taken. Context: The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 3. A power stage component energizes the injection system transistors and simultaneously observes the current flow in the high-side and low-side switching branch by sensing resistors. If there is a deviation from the expected current flow the component detects specific errors and reports them to the ECU. This error message is then rearranged so it holds information on performed injections, errors of cylinders on the same bank, bank specific errors and cylinder specific errors. The rearranged error message is then compared to applicable error patterns and if there is a match the failure corresponding to the matched pattern is output. If an error message does not match any pattern the defect is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of a short circuit of the high side to the low side or ground over 3 camshaft revolutions. As a result of this error an individual cylinder or bank is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent (without a healing possibility, once tested by switching on the component to see if the defect is still present) and others evoke an irreversible or reversible shut off of the engine to be executed. Cause: The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the injector output power driver stage. Possible failure modes: 1. Faulty cylinder 3 solenoid windings. 2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness). 3. Faulty ECU, ECU hardware or software. Solution: 1. Verify this fault code is still present and in an active state. 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, return machine to proper operation. 2. Carefully disconnect the engine cylinder harness from the ECU at ECU cylinder harness connector X-939. Use a multi-meter to check the resistance, on the cylinder harness side of connector X-939, between pins 1 and 31. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, leave ECU cylinder connector X-939 disconnected and continue with step 3. B. If the resistance was lower than range minimum, continue with step 6. 3. Use a multi-meter to check for continuity, on the ECU cylinder harness side of connector X-939, from pin 1 to chassis ground and pin 31 to chassis ground. There should not be continuity. A. If there was continuity on either or both pins to chassis ground, continue with step 4. B. If there was no continuity on either pin to chassis ground, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs, replace the ECU.

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4. Disconnect the engine cylinder harness from the injector (valve) cover at connector X-940. Use a multi-meter to check for continuity, on the injector (valve) cover side of connector X-940 from pin D to chassis ground and pin C to chassis ground. There should not be continuity. A. If there was continuity on either or both pins to chassis ground, leave connector X-940 disconnected and continue with step 5. B. If there was no continuity on either pin to chassis ground, there is a short to ground condition in the engine cylinder harness between Valve cover connector X-940 and ECU to cylinder harness connector X-939. Locate and repair the grounded conductor. 5. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 3 injector at connector X-953 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the injector, from terminal 1 to chassis ground. There should not be continuity. A. If there is continuity, Cylinder 3 injector's solenoid coil has failed, replace the injector. B. If there is no continuity, there is a short to ground condition in Cylinder 3 injector circuit, between connector X-953 and connector X-940. Locate and repair the grounded conductor. 6. Disconnect the engine cylinder harness from the injector (valve) cover at connector X-940 and use a multi-meter to check the resistance on the injector (valve) cover side of connector X-940 between pins D and C. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, there is a short circuit condition in the engine injector harness between the injector (valve) cover connector X-940 and ECU cylinder harness connector X-939, locate and repair the short circuit. B. If the resistance was lower than range minimum, continue with step 7. 7. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 3 injector at connector X-953 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder 3 injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, there is a short circuit condition in the injector harness, between Cylinder 3 injector connector X-953 and connector X-940. Locate and repair the shorted conductors. B. If the resistance was lower than minimum range, the Cylinder 3 injector solenoid coil has failed. Replace the injector.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3079-Injector cylinder 2 - short circuit Control Module : ECU NOTE: This diagnostic procedure requires a good quality multi-meter to be able to take accurate resistance measurements. The meter should be able to measure to a resolution of 0.1 ohms. Some of the measurements required to be taken, could be as low as 0.4 ohms (typical injector solenoid coil resistance is 0.4 - 0.5 ÎŠ) and any inaccuracies in the DMM could cause a technician to take the wrong diagnostic path. NOTE: Make sure that the multi-meter's test lead resistance is taken into account when resistance measurements are taken. Record the multi-meter's test lead resistance by touching the leads together on the lowest Ohms scale and mentally recording the resistance value. Subtract this value from the actual resistance measurement taken. Context: The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 2. A power stage component energizes the unit injection system transistors and simultaneously observes the current flow in the high-side and low-side switching branch by sensing resistors. If there is a deviation from the expected current flow the component detects specific errors and reports them to the ECU. This error message is then rearranged so it holds information on performed injections, errors of cylinders on the same bank, bank specific errors and cylinder specific errors. The rearranged error message is then compared to applicable error patterns and if there is a match the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of a short circuit of the high side to the low side or ground over 3 camshaft revolutions. As a result of this error an individual cylinder or bank is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent (without a healing possibility, once tested by switching on the component to see if the defect is still present). and others evoke an irreversible or reversible shut off of the engine to be executed. Cause: The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the injector output power driver stage. Possible failure modes: 1. Faulty cylinder 2 solenoid windings. 2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness). 3. Faulty ECU, ECU hardware or software. Solution: 1. Verify this fault code is still present and in an active state. 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, return machine to proper operation. 2. Carefully disconnect the engine cylinder harness from the ECU at ECU cylinder harness connector X-939. Use a multi-meter to check the resistance, on the cylinder harness side of connector X-939, between pins 2 and 46. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, leave ECU cylinder connector X-939 disconnected and continue with step 3. B. If the resistance was lower than range minimum, continue with step 6. 3. Use a multi-meter to check for continuity, on the ECU cylinder harness side of connector X-939, from pin 2 to chassis ground and pin 46 to chassis ground. There should not be continuity. A. If there was continuity on either or both pins to chassis ground, continue with step 4. B. If there was no continuity on either pin to chassis ground, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs, replace the ECU.

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4. Disconnect the engine cylinder harness from the injector (valve) cover at connector X-940. Use a multi-meter to check for continuity, on the injector (valve) cover side of connector X-940 from pin H to chassis ground and pin G to chassis ground. There should not be continuity. A. If there was continuity on either or both pins to chassis ground, leave connector X-940 disconnected and continue with step 5. B. If there was no continuity on either pin to chassis ground, there is a short to ground condition in the engine cylinder harness between Valve cover connector X-940 and ECU to cylinder harness connector X-939. Locate and repair the grounded conductor. 5. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 2 injector at connector X-952 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the injector, from terminal 1 to chassis ground. There should not be continuity. A. If there is continuity, Cylinder 2 injector's solenoid coil has failed, replace the injector. B. If there is no continuity, there is a short to ground condition in Cylinder 2 injector circuit, between connector X-952 and connector X-940. Locate and repair the grounded conductor. 6. Disconnect the engine cylinder harness from the injector (valve) cover at connector X-940 and use a multi-meter to check the resistance on the injector (valve) cover side of connector X-940 between pins H and G. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, there is a short circuit condition in the engine injector harness between the injector (valve) cover connector X-940 and ECU cylinder harness connector X-939, locate and repair the short circuit. B. If the resistance was lower than range minimum, continue with step 7. 7. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 2 injector at connector X-952 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder 2 injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, there is a short circuit condition in the injector harness, between Cylinder 2 injector connector X-952 and connector X-940. Locate and repair the shorted conductors. B. If the resistance was lower than minimum range, the Cylinder 2 injector solenoid coil has failed. Replace the injector.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3083-Injector cylinder 4 - short circuit Control Module : ECU NOTE: This diagnostic procedure requires a good quality multi-meter to be able to take accurate resistance measurements. The meter should be able to measure to a resolution of 0.1 ohms. Some of the measurements required to be taken, could be as low as 0.4 ohms (typical injector solenoid coil resistance is 0.4 - 0.5 ÎŠ) and any inaccuracies in the DMM could cause a technician to take the wrong diagnostic path. NOTE: Make sure that the multi-meter's test lead resistance is taken into account when resistance measurements are taken. Record the multi-meter's test lead resistance by touching the leads together on the lowest Ohms scale and mentally recording the resistance value. Subtract this value from the actual resistance measurement taken. Context: The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 4. A power stage component energizes the unit injection system transistors and simultaneously observes the current flow in the high-side and low-side switching branch by sensing resistors. If there is a deviation from the expected current flow the component detects specific errors and reports them to the ECU. This error message is then rearranged so it holds information on performed injections, errors of cylinders on the same bank, bank specific errors and cylinder specific errors. The rearranged error message is then compared to applicable error patterns and if there is a match the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of a short circuit of the high side to the low side or ground over 3 camshaft revolutions. As a result of this error an individual cylinder or bank is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent (without a healing possibility, once tested by switching on the component to see if the defect is still present). and others evoke an irreversible or reversible shut off of the engine to be executed. Cause: The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the injector output power driver stage. Possible failure modes: 1. Faulty cylinder 4 solenoid windings. 2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness). 3. Faulty ECU, ECU hardware or software. Solution: 1. Verify this fault code is still present and in an active state. 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, return machine to proper operation. 2. Carefully disconnect the engine cylinder harness from the ECU at ECU cylinder harness connector X-939. Use a multi-meter to check the resistance, on the cylinder harness side of connector X-939, between pins 17 and 48. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, leave ECU cylinder connector X-939 disconnected and continue with step 3. B. If the resistance was lower than range minimum, continue with step 6. 3. Use a multi-meter to check for continuity, on the ECU cylinder harness side of connector X-939, from pin 17 to chassis ground and pin 48 to chassis ground. There should not be continuity. A. If there was continuity on either or both pins to chassis ground, continue with step 4. B. If there was no continuity on either pin to chassis ground, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs, replace the ECU.

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4. Disconnect the engine cylinder harness from the injector (valve) cover at connector X-940. Use a multi-meter to check for continuity, on the injector (valve) cover side of connector X-940 from pin E to chassis ground and pin F to chassis ground. There should not be continuity. A. If there was continuity on either or both pins to chassis ground, leave connector X-940 disconnected and continue with step 5. B. If there was no continuity on either pin to chassis ground, there is a short to ground condition in the engine cylinder harness between Valve cover connector X-940 and ECU to cylinder harness connector X-939. Locate and repair the grounded conductor. 5. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 4 injector at connector X-954 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the injector, from terminal 1 to chassis ground. There should not be continuity. A. If there is continuity, Cylinder 4 injector's solenoid coil has failed, replace the injector. B. If there is no continuity, there is a short to ground condition in Cylinder 4 injector circuit, between connector X-954 and connector X-940. Locate and repair the grounded conductor. 6. Disconnect the engine cylinder harness from the injector (valve) cover at connector X-940 and use a multi-meter to check the resistance on the injector (valve) cover side of connector X-940 between pins E and F. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, there is a short circuit condition in the engine injector harness between the injector (valve) cover connector X-940 and ECU cylinder harness connector X-939, locate and repair the short circuit. B. If the resistance was lower than range minimum, continue with step 7. 7. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 4 injector at connector X-954 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder 4 injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, there is a short circuit condition in the injector harness, between Cylinder 4 injector connector X-954 and connector X-940. Locate and repair the shorted conductors. B. If the resistance was lower than minimum range, the Cylinder 4 injector solenoid coil has failed. Replace the injector.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3088-Crankshaft sensor - no signal Control Module : ECU Context: The Engine Control Unit (ECU) has reported an error with the monitoring of the Increment speed (Crankshaft speed) sensor. If the engine has a defective Crankshaft speed sensor it can run off the Segment speed (Camshaft speed) sensor. This is referred to as BACKUP mode. Cause: The ECU has determined that there is no signal from the Crankshaft speed sensor. The engine is now operating in BACKUP mode. Possible failure modes: 1. Faulty Crankshaft speed sensor. 2. Faulty electrical wiring and/or connections. 3. Faulty ECU, or ECU supply voltages or grounds. Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Remove Crankshaft speed sensor connector X-965 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the Crankshaft speed sensor. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace Crankshaft speed sensor if damaged. B. If no damage is determined, leave connector disconnected and proceed to step 3. 3. Check for Faulty CKP, Engine flywheel RPM, sensor. Place the ignition switch OFF. Connect the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the sensor side of the terminals. Measure for resistance from the Crankshaft speed sensor connector X-965 pin 1 to pin 2. There should be 750 - 1000 ÎŠ A. If the resistance test does not fall in the specified range, replace Crankshaft speed sensor. B. If the resistance test does fall in the specified range, leave connector disconnected and proceed to step 4. 4. Check Output of Crankshaft speed sensor. Place the ignition switch OFF when setting up the test. Make the following electrical tests in the table below. There will be (2) types of tests (in-line and single ended) that will need to be performed which use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185. Reference the descriptions below to make the proper electrical connections for each test type. Single Ended Test Lead Connection Test (Standalone Crankshaft speed sensor Test) Remove Crankshaft speed sensor connector and connect the above mentioned special test lead to the Crankshaft speed sensor. Start the engine and measure the (AC) voltage using a multi-meter across the breakout alligator clips from the test leads. Use the test table below to determine the measurement results. In-Line Test Lead Connection Test: Remove Crankshaft speed sensor connector and connect the above mentioned special test lead in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process. Start the engine and measure the (AC) voltage using a multi-meter across the breakout alligator clips from the test leads. Use the test table below to determine the measurement results. Note: 47538922 29/05/2013

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The engine will be running off the Camshaft speed sensor during the single ended test, if it isn't already (based on the fault code type). The engine can also be very hard to start when running exclusively off the Camshaft speed sensor. The ECU needs to see a few revolutions of the camshaft to be able to use this information to start the engine.. Test Type 1. Voltage (AC) - Single ended connection at low RPM ( 1000 - 1100 RPM) 2. Voltage (AC) - Single ended connection at high RPM ( 2000 - 2200 RPM) 3. Voltage (AC) - In-line connection at low RPM ( 1000 - 1100 RPM) 4. Voltage (AC) - In-line connection at high RPM ( 2000 - 2200 RPM)

From To Expected Results Crankshaft speed sensor Crankshaft speed sensor Approx. 16 - 18 volts (AC) connector X-965 pin 1 connector X-965 pin 2 Crankshaft speed sensor Crankshaft speed sensor Approx. 32 - 34 volts (AC) connector X-965 pin 1 connector X-965 pin 2 Crankshaft speed sensor Crankshaft speed sensor Approx. 10 - 12 volts (AC) connector X-965 pin 1 connector X-965 pin 2 Crankshaft speed sensor Crankshaft speed sensor Approx. 14 - 17 volts (AC) connector X-965 pin 1 connector X-965 pin 2

A. If the voltage test was successful, proceed to step 6. B. If the voltage test was not successful for any of the single ended connections, replace the sensor. C. If the voltages encountered during testing are low and the sensor was replaced on a prior diagnostic procedure of this type, ensure the Crankshaft speed sensor is installed properly. D. If the voltage test was successful for the single ended connections and not for any of the in-line connections, leave the connector disconnected and proceed to step 5. 5. Check for Faulty Wiring. Place the ignition switch OFF. Perform continuity tests between connector X-965 and connector X-939 on ECU engine harness. Flex harness during test to check for any intermittent operation. Use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X-965. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the multi-meter to connector X-939. Make sure the multi-meter's test lead resistance is taken into account when taking continuity measurements. See test table below. Important Note: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type 1. Continuity

2. Continuity

3. Short Circuit

From To Crankshaft speed sensor ECU engine harness conconnector X-965 pin: 1 nector X-939 pin: 44, wire 415 (WH) Crankshaft speed sensor ECU engine harness conconnector X-965 pin: 2 nector X-939 pin: 59, wire 423 (RD) ECU engine harness con- ECU engine harness connector X-939 pin: 44, wire nector X-939 pin: 59, wire 415 (WH) 423 (RD)

Expected Results Approx. 0 - 0.10 ohms

Approx. 0 - 0.10 ohms

Open Circuit

A. If continuity/shorts test is successful, go to step 6. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 6. Check for ECU Voltages and Ground Continuity. Use product schematic. Place the ignition switch OFF. Remove connector X-937 from the ECU. Place the ignition switch ON to check for voltage at the appropriate pins defined in the test table below. Place the ignition switch OFF to check for continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to connector X-937. Make sure the DMM's test lead resistance is taken into account when making any continuity measurements. Important Note:

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Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type 1. Voltage

2. Continuity

From To X-937 pin 1 (RD/BK), pin Ground (engine block) 3 (RD/YE), pin 5 (RD/YE), pin 54 (OR) X-937 pin 2 (BK), pin 4 Ground (engine block) (BK), pin 6 (BK)

Expected Results Approx. 12 volts (DC)

Approx. 0 - 0.10 ohms

A. If the voltages and ground paths are correct and the Crankshaft speed sensor was not replaced on a prior diagnostic procedure of this type, replace the sensor. B. If the voltages and ground paths are correct and the Crankshaft speed sensor was replaced on a prior diagnostic procedure of this type and the sensor mechanical alignment and spacing was verified, re-initialize the ECU as if it was blank (new) and load the appropriate data-set. C. If the voltages and ground paths are correct and the ECU was re-initialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to product schematics and determine root cause of power and/or continuity problem(s).

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18) Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3089-Crankshaft sensor - invalid signal Control Module : ECU Context: The Engine Control Unit (ECU) has reported an error with the monitoring of the Crankshaft speed sensor. If the engine has a defective Crankshaft speed sensor it can run off the Camshaft speed sensor. This is referred to as BACKUP mode. Cause: The ECU has determined that there are errors in the signal from the Crankshaft speed sensor. Possible failure modes: 1. Faulty Crankshaft speed sensor. 2. Faulty electrical wiring and/or connections. 3. Faulty ECU, supply voltages or ground paths. Solution: 1. Verify the fault code is present and active. A. If fault code is present and active, continue with step 2. B. If fault code is no longer present, return machine to proper operation. 2. Inspect the Crankshaft speed sensor. Remove the Crankshaft speed sensor connector X-965 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect the connector portion of the Crankshaft speed sensor. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace Crankshaft speed sensor if damaged. B. If no damage is determined, proceed to step 3. 3. Check internal resistance of Crankshaft speed sensor. Remove Crankshaft speed sensor connector, X-965, and connect the test lead labeled "Cam/Crankshaft Sensor Interface Harness" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to the Crankshaft speed sensor to access the sensor terminals. Use a multi-meter to measure the resistance between pins 1 and 2 of the Crankshaft speed sensor. There should be between 825 - 975 Ω at 20 °C (68 °F). A. If the resistance is not within the specified range, replace the Crankshaft speed sensor. B. If the resistance is within the specified range, proceed to step 4. 4. Check the Crankshaft speed sensor output. With the "Cam/Crankshaft Sensor Interface Harness" from the Tier II (NEF) Diagnostic Repair Kit 380040185 connected to the Crankshaft speed sensor, use a multi-meter to check for voltage (AC), while starting the engine, between pins 1 and 2 of the Crankshaft speed sensor connector, X-965. There should be a minimum of .50 V (AC) while cranking and a higher reading once the engine starts. A. If the voltage is less than .50 V (AC), replace the sensor. B. If the voltage is above .50 V (AC), proceed to step 5. 5. Check for faulty wiring between the Crankshaft speed sensor and the ECU. Measure resistance between the Crankshaft speed sensor, X-965, pin 2, and the ECU engine connector, X-939pin 59, wire 423 (RD). A. If there is continuity, go to step 6. B. If there is no continuity, find and repair the damaged wiring between connector X-965, pin 2 and X-939pin 59, wire 423 (RD). 6. Check voltage and ground supply to ECU. Disconnect ECU vehicle connector X-937 and use a multi-meter to verify the ECU has sufficient supply voltage and ground paths. Use the table below as a reference. 47538922 29/05/2013

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Test Type 1. Voltage

2. Continuity

From To X-937 pin 1 (RD/BK), pin Ground (engine block) 3 (RD/YE), pin 5 (RD/YE), pin 54 (OR) X-937 pin 2 (BK), pin 4 Ground (engine block) (BK), pin 6 (BK)

Expected Results Approx. 12 volts (DC)

Approx. 0 - 0.10 ohms

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18) Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3090-Camshaft sensor - no signal Control Module : ECU Context: The Engine Control Unit (ECU) has reported an error with the monitoring of the Segment speed sensor (Camshaft speed sensor). If the engine has a defective Camshaft speed sensor it can run off the Increment speed sensor (Crankshaft speed sensor). Diagnostics is active if voltage is present at terminal 15 (Ignition On), the current engine speed is above 50 RPM, no error in the Crankshaft speed sensor is present and the sensor supply voltage ( 5 volts DC) is not defective. Cause: The ECU has determined that there is no signal from the Camshaft speed sensor. Possible failure modes: 1. Faulty connector 2. Incorrectly installed camshaft speed sensor 3. Faulty camshaft speed sensor 4. Faulty harness Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check the camshaft speed sensor connector X-962 and the engine controller connector X-939. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Ensure that the camshaft sensor mechanical operation is okay. Remove the sensor and ensure it is clean and not damaged. A. If a fault with the camshaft sensor is indicated, repair as necessary. B. If a fault with the camshaft sensor is not indicated, ensure the sensor is fitted correctly, continue to step 4 4. Check for + 5 V. A. Disconnect connector X-962. Turn the ignition key switch ON. Measure the voltage between connector X-962 pin 3 and ground. If approximately 5 V is not indicated, repair or replace the harness as required. B. If approximately 5 V is indicated, continue to step 5 5. Check for an open ground circuit. A. Check between connector X-962 pin 1 and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 6 6. Check for a short to +Ve voltage. A. Turn the ignition key switch ON. Check between connector X-962 pin 2 and ground. If a voltage is indicated, repair or replace the harness as required.

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B. If a voltage is not indicated, continue to step 7 7. Check for a short to ground. A. Turn the ignition key switch OFF. Check between connector X-962 pin 2 and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 8 8. Check for an open circuit. A. Disconnect connector X-939. Check between connector X-962 pin 2 and X-939 pin 14, wire 399 (BR/BK). If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the camshaft speed sensor.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3091-Camshaft sensor - invalid signal Control Module : ECU Context: The Engine Control Unit (ECU) has reported an error with the monitoring of the Segment speed sensor (Camshaft speed sensor). If the engine has a defective Camshaft speed sensor it can run off the Increment speed sensor (Crankshaft speed sensor). Cause: The ECU has determined that there is a plausibility error between the phasing of the Crankshaft speed sensor and the Camshaft speed sensor signals. The signal from the Camshaft speed sensor is either intermittent or does not exist. Possible failure modes: 1. Faulty Camshaft speed sensor. 2. Camshaft speed sensor is not mechanically installed correctly. 3. Faulty electrical wiring and/or connections. 4. Faulty ECU or ECU supply voltages or ground. Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check the camshaft speed sensor connector X-962 and the engine controller connector X-939. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Ensure that the camshaft sensor mechanical operation is okay. Remove the sensor and ensure it is clean and not damaged. A. If a fault with the camshaft sensor is indicated, repair as necessary. B. If a fault with the camshaft sensor is not indicated, ensure the sensor is fitted correctly, continue to step 4 4. Check for + 5 V. A. Disconnect connector X-962. Turn the ignition key switch ON. Measure the voltage between connector X-962 pin 3 and ground. If approximately 5 V is not indicated, repair or replace the harness as required. B. If approximately 5 V is indicated, continue to step 5 5. Check for an open ground circuit. A. Check between connector X-962 pin 1 and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 6 6. Check for a short to +Ve voltage. A. Turn the ignition key switch ON. Check between connector X-962 pin 2 and ground. If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 7 47538922 29/05/2013

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7. Check for a short to ground. A. Turn the ignition key switch OFF. Check between connector X-962 pin 2 and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 8 8. Check for an open circuit. A. Disconnect connector X-939. Check between connector X-962 pin 2 and X-939 pin 14, wire 399 (BR/BK). If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the camshaft speed sensor.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3093-Crankshaft sensor and camshaft sensor - offset between speed signals too high Control Module : ECU Context: The Engine Control Unit (ECU) has reported an error with the phase relationship between the Increment speed sensor (Crankshaft speed sensor) and the Segment speed sensor (Camshaft speed sensor). The engine will alternatively use a redundant angular system which is based on the Crankshaft speed sensor. Diagnostics is active under these conditions: 1) terminal 40 (Key On) is active, 2) current engine speed is above 50 RPM, 3) no error is reported for the camshaft speed sensor and 4) sensor supply voltage ( 5 volts DC) is not defective . Cause: The ECU has determined that there is a phase relationship error between the Crankshaft speed sensor and the Camshaft speed sensor. Possible failure modes: 1. Faulty Camshaft speed sensor or Crankshaft speed sensor. 2. Camshaft speed sensor or Crankshaft speed sensor are not mechanically installed correctly. 3. Faulty electrical wiring and/or connections. Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other camshaft or crankshaft related error codes. A. If other camshaft or crankshaft related error codes are displayed, continue to these tests. B. If no other camshaft or crankshaft related error codes are displayed, continue to step 3 3. Check the crankshaft speed sensor connector X-965, the camshaft speed sensor connector X-962 and the engine controller connector X-939. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 4 4. Ensure that the crankshaft and camshaft sensor mechanical operation is okay. Remove the sensors and ensure they are clean and not damaged. A. If a fault with the crankshaft or camshaft sensor is indicated, repair as necessary. B. If a fault with the crankshaft or camshaft sensor is not indicated, ensure the sensors are fitted correctly. If the fault re-occurs, remove and replace the engine controller.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3096-CAN-Bus - ECU in bus-off state or CAN-Bus fault Control Module : ECU Possible failure modes: 1. Faulty connectors 2. Wiring fault 3. Engine control unit ( ECU) fault Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the tractor under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other error codes displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check the connector of the instrument cluster ( ADIC) X-450 and the connector of the engine control unit ( ECU) X-937. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 4 4. Check all power supplies and grounds to the engine control unit ( ECU) . A. If a fault is indicated, repair or replace the harness as required. B. If no faults are indicated, continue to step 5 5. Check for an open circuit on the CAN BUS. A. Disconnect the connector ( ADIC) X-450 and the connector ( ECU) X-937. Check between: X-937 ( CAN_H) pin 24, wire 0.75 (YE) and X-450 ( CAN_H) pin 3, wire 0.75 (YE) X-937 ( CAN_L) pin 25, wire 0.75 (GN) and X-450 ( CAN_L) pin 4, wire 0.75 (GN) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the engine control unit ( ECU).

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INT / WE markets Wire harnesses - Electrical schematic frame 01 (55.100.DP-C.20.E.01) NA market Wire harnesses - Electrical schematic frame 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic frame 11 (55.100.DP-C.20.E.11) Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17) Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3102-Common rail pressure sensor - signal too low Control Module : ECU Context: The engine control unit (ECU) has sensed that the Fuel Pressure sensor signal is too low. The test frequency of the sensor is every 10 ms and if the signal is below 0.324 V for over 200 ms, the error is set. Once set the ECU will, instead of using the peak rail pressure value of the last 10 ms and the current rail pressure, output a substitute value from a curve (MAP) in the ECU depending on engine speed and injection quantity. Cause: The Rail Pressure sensor signal is too low. Possible failure modes: 1. Faulty Rail Pressure sensor. 2. Faulty circuit wiring, shorted to low source. 3. Faulty ECU, hardware or software. Solution: 1. Disconnect the engine sensor harness from the ECU at ECU engine connector X-939 and place the ignition key switch in the "On" position. Use a multi-meter check the voltage on the ECU from pin 11 to pin 26. There should be 5 V. A. If there is 5 V reconnect ECU engine connector and continue with step 2 B. If there is less than 5 V, there is a failure inside the ECU, replace the ECU. 2. Disconnect the engine sensor harness from the Fuel Pressure sensor and place the Key switch in the "On" position. Use a multi-meter check the voltage on the engine harness side of Fuel pressure sensor connector X-967 from pin 3 to pin 1. There should be 5 V. A. If there is 5 V leave the Fuel pressure sensor connector disconnected and continue with step 3 B. If there is less than 5 V, there is a short to low source in the sensor circuit wiring, leave the Fuel pressure sensor connector disconnected and continue with step 4 3. Disconnect the engine sensor harness from the ECU at ECU engine connector X-939. Use a multi-meter to test for continuity between the engine sensor harness side of ECU engine connector X-939 pin 41,wire 413 (RD/GN) and ground and also between Fuel pressure sensor connector X-967 pin 2 and ground. There should be no continuity. A. If there is continuity on either or both tests, there is a short to low source in the sensor signal wire, locate and repair the short to low source. B. If there is no continuity, either the sensor has failed or the ECU is faulty. Replace the common rail pressure sensor and if the fault reoccurs reload the ECU software. If the fault reoccurs after replacing the sensor and reloading software, replace the ECU . 4. Disconnect the engine sensor harness from the ECU at ECU engine connector X-939. Use a multi-meter to test for continuity between the engine sensor harness side of ECU engine connector X-939 pin 11, wire 396 (GN/WH) and ground and also between Fuel pressure sensor connector X-967 pin 3 and ground. There should be no continuity. A. If there is continuity, on either or both tests, there is a short to low source in the sensor source wire. Locate and repair the short to low source. B. If there is no continuity, on either or both tests, there is a short to low source in the sensor ground reference wire. Locate and repair the short to low source.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3104-Common rail relief valve - open Control Module : ECU Context: The engine control unit (ECU) has determined that the Pressure Relief Valve (PRV) is open. Normally the fuel pressure in the rail is regulated by the metering unit of the high pressure pump. However, if this component is malfunctioning the rail pressure can rise to critical levels. For this reason the common rail has a Pressure Relief Valve (PRV) which is a mechanical safety valve (no electrical connectors) that opens at a certain pressure level. An opening of the PRV is detected by evaluating the gradient of the rail pressure (calculated by the ECU). If the PRV does not open on its own after exceeding the pressure threshold it can also be forced open by a so-called 'kickoff' or pressure shock when the metering valve of the high pressure fuel pump is set to maximum possible quantity. Once the PRV has been opened it will remain open as long as the engine is running. A defective common rail pressure sensor, as judged by the ECU, which evokes a kickoff (pressure shock) or a defect in an injection relevant component (small leak) can cause this error to occur. This fault will only be cleared after an ECU reset. Possible failure modes: 1. Faulty Rail Pressure sensor, signal not plausible. 2. Faulty common rail fuel system, small leak. 3. Faulty ECU, hardware or software. Solution: 1. Use EST to check for other Rail Pressure sensor and injector (cylinder or bank) errors. A. If Rail Pressure sensor or injector errors exist, follow troubleshooting procedure for existing Rail Pressure sensor or injector error. B. If no Rail Pressure sensor or injector errors exist, continue with step 2 2. Check common rail fuel system for leaks. A. If common rail fuel system leak is found, repair as required. B. If no common rail fuel system leak is found, continue with step 3 3. Visually inspect connector X-967 and connector X-939 for electrical integrity. A. If damage or connectivity issues are discovered, repair, clean or replace as required. B. If no damage or connectivity issues are discovered, replace Rail Pressure sensor and restart engine. If error reoccurs continue with step 4 4. Visually inspect connector X-939 for electrical integrity. A. If damage or connectivity issues are discovered, repair, clean or replace as required. B. If no damage or connectivity issues are discovered, continue with step 5 5. Visually inspect injector connectors X-951, X-954, X-952 and X-953 for electrical integrity. A. If damage or connectivity issues are discovered, repair, clean or replace as required. B. If no damage or connectivity issues are discovered, continue with step 6 6. Reload ECU software. A. If error reoccurs after trying to reload software, replace ECU. B. If error has been resolved, continue with normal operation of machine.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3106-Pressure relief valve reached maximum allowed opening count Control Module : ECU Context: The engine control unit (ECU) has determined that the Pressure Relief Valve (PRV) has been forced to open too many times. Normally the fuel pressure in the rail is regulated by the metering unit of the high pressure pump. However, if this component is malfunctioning the rail pressure can rise to critical levels. The PRV is a mechanical safety valve (no electrical connectors) that opens to relieve excess fuel pressure. The PRV opening is detected by evaluating the gradient of the rail pressure (calculated by the ECU). This fault will only be cleared after an ECU reset is performed using the EST. Possible failure modes: 1. Fuel system failure. 2. The wiring harness may be damaged. 3. Faulty ECU, improper data set. Solution: 1. Using the EST, verify the fault code is present. A. If the fault code is present, proceed to step 2. B. If the fault code is not present, return the machine to operation. 2. Using the EST, verify there are no other fuel system failures. A. No other failures, continue with step 3. B. Other failure - Repair other failures, clear fault code(s), and retest. If code does not reoccur, return the machine to service. 3. Visually inspect the connectors for damage, bent, or corroded terminals and locking tabs. Check the harnesses for broken, chaffed, or rubbed wires. Verify that the connectors and/or pins are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST diagnostic screen. A. If no damage is found, proceed to step 4. B. If damage is found, repair damaged components. Using EST to clear the fault code(s). Operate the equipment to verify repairs. If repairs are complete, return the machine to operation. 4. Using the EST, verify the ECU is at the current data set. If the data set is not current, using the EST, update the ECU to the current data set. A. If the fault code is still active, proceed to step 5. B. If the fault does not reoccur, return the machine to service. 5. Test the fuel rail pressure. A. If the fuel pressure is found in excess of 148500 kPa (21538.1 psi) the valve is stuck closed. Replace the valve. Using the EST, clear the fault code. Operate the machine to verify repairs. If repairs are complete, return the machine to operation. B. If low fuel pressure is found, the PRV is stuck open. Replace the valve. Using the EST, clear the fault code. Operate the machine to verify repairs. If repairs are complete, return the machine to operation.

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3107-High pressure pump solenoid valve - short circuit to battery Control Module : ECU Context: The engine control unit (ECU) has determined that a short to high source circuit condition exists in the fuel high pressure pump low side circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common rail. The metering unit is closed-loop controlled by both main relay 1 (high side) and a low side power stage (Main Relay 1 is an electronic control circuit within the ECU, providing source voltage to devices external to the ECU. The low side power stage works in conjunction with the Main Relay 1 source, providing sensing and current limiting for the circuit). The monitoring at low side is stopped if a short circuit to ground at the high side (main relay 1) is detected or it is switched off for some reason. Failure detection of is only possible if the low side power stage is switched on. With the current settings, the monitoring is shut off during after-run. This error is the result of the power stage hardware report of 'short circuit to battery' (on the low side of the metering unit) longer than 0.0 (zero) milliseconds and once the permanent error is detected the power stage is switched off. Cause: Fuel high pressure pump circuit is shorted to a high source. Possible failure modes: 1. Faulty fuel high pressure pump control circuit, shorted to a high source. 2. Faulty ECU, hardware or software. Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Disconnect the Engine Injector harness from the ECU at connector X-939 and place the Key switch in the "On" position. Use a multi-meter to test for voltage from the Engine Injector harness side of connector X-939 pin 60, wire 424 (GY/WH) to chassis ground. There should be no voltage. A. If there is voltage, locate and repair the short to the voltage source. B. If there is no voltage, continue with step 3 3. Disconnect the Engine Injector harness from the fuel high pressure pump at connector X-970 and use a multi-meter to check the resistance of the fuel high pressure pump solenoid coil. There should be a small amount of resistance. A. If there is a small amount of resistance, try reloading the ECU software and if the error reoccurs, replace the ECU. B. If there is no resistance, the fuel high pressure pump solenoid coil has failed, replace the solenoid.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3108-High pressure pump solenoid valve - short circuit to ground Control Module : ECU Context: The engine control unit (ECU) has determined that a short to low source circuit condition exists in the fuel high pressure pump low side circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common rail. The metering unit is closed-loop controlled by both main relay 1 (high side) and a low side power stage (Main Relay 1 is an electronic control circuit within the ECU, providing source voltage to devices external to the ECU. The low side power stage works in conjunction with the Main Relay 1 source, providing sensing and current limiting for the circuit). The monitoring at low side is stopped if a short circuit to ground at the high side (main relay 1) is detected or it is switched off for some reason. Failure detection of is only possible if the low side power stage is switched off. With the current settings, the monitoring is shut off during after-run. This error is the result of the power stage hardware report of 'short circuit to ground' (on the low side of the metering unit) longer than 0.28 seconds and the power stage has most likely switched off. Cause: Fuel high pressure pump circuit is shorted to a low source. Possible failure modes: 1. Faulty fuel high pressure pump control circuit, shorted to a low source. 2. Faulty ECU, hardware or software. Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Disconnect the Engine Injector harness from the ECU at connector X-939. Use a multi-meter to test for continuity from the Engine Injector harness side of connector X-939 pin 60, wire 424 (GY/WH) to ground. There should be no continuity. A. If there is continuity, continue with step 3 B. If there is no continuity, try reloading the ECU software and if the error reoccurs, replace the ECU. 3. Disconnect the Engine Injector harness from the Fuel high pressure pump at connector X-970 and use a multimeter to check for continuity on the fuel high pressure pump side of connector X-970 pins 1 and 2 to chassis ground. There should be no continuity on either pin to ground. A. If there is continuity on either pin, the fuel high pressure pump solenoid coil has failed, replace the solenoid. B. If there is no continuity on either pin, there is a short to low source in the Engine Injector harness, locate and repair the short to ground.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3112-Common rail pressure sensor - signal too high Control Module : ECU Context: The engine control unit (ECU) has sensed that the Fuel Pressure sensor signal is too high. The test frequency of the sensor is every 10 ms and if the signal is in excess of 4.86 V for over 200 ms, the error is set. Once set the ECU will, instead of using the peak rail pressure value of the last 10 ms and the current rail pressure, output a substitute value from a curve (MAP) in the ECU depending on engine speed and injection quantity. Cause: The Fuel Pressure sensor signal is too high. Possible failure modes: 1. Faulty Fuel Pressure sensor. 2. Faulty circuit wiring, shorted to high source. 3. Faulty ECU, hardware or software. Solution: 1. Disconnect the engine sensor harness from the ECU at ECU engine connector X-939 and place the Key switch in the "On" position. Using a multi-meter check the voltage on the ECU engine connector X-939 from pin 11 to pin 26. There should be 5 V. A. If there is 5 V reconnect ECU engine connector X-939 and continue with step 2 B. If there is greater than 5 V, there is a failure inside the ECU, replace the ECU. 2. Disconnect the engine sensor harness from the Rail Pressure sensor connector X-967 and place the Key switch in the "On" position. Use a multi-meter check the voltage on the engine harness side of Rail pressure sensor connector X-967 from pin 1 to pin 3. There should be 5 V. A. If there is 5 V leave the Rail pressure sensor connector disconnected and continue with step 3 B. If there is greater than 5 V, there is a short to high source in the sensor circuit wiring, leave the Rail pressure sensor connector X-967 disconnected and continue with step 4 3. Disconnect the engine sensor harness from the ECU at ECU engine connector X-939. Use a multi-meter test for voltage between the engine sensor harness side of ECU engine connector X-939 pin 41, wire 413 (RD/GN) and ground and also between Rail pressure sensor connector X-967 pin 2 and ground. There should be no voltage. A. If there is voltage on either or both tests, there is a short to high source in the sensor signal wire 413 (RD/GN), locate and repair the short to high source. B. If there is no voltage, either the sensor has failed or the ECU is faulty. Replace the Rail Pressure sensor and if the fault reoccurs reload the ECU software. If the fault reoccurs after replacing the sensor and reloading software, replace the ECU. 4. Disconnect the engine sensor harness from the ECU at ECU engine connector X-939. Use a multi-meter test for voltage between the engine sensor harness side of ECU engine connector X-939 pin 11, wire 396 (GN/WH) and ground and also between Rail pressure sensor connector X-967 pin 3 and ground. There should be no voltage. A. If there is voltage, on either or both tests, there is a short to high source in the sensor source wire. Locate and repair the short to high source. B. If there is no voltage, on both tests, there is a short to high source in the sensor ground reference wire. Locate and repair the short to high source.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3126-Hand throttle - signal 1 too high Control Module : ECU Possible failure modes: 1. Faulty connector 2. Faulty hand throttle sensor 3. Faulty harness 4. Faulty controller Solution: 1. Check the hand throttle potentiometer in H9 Channel 90. A. Operate the hand throttle . If the values displayed do not change continuously between 200 - 4800 mV, continue to step 2 B. If the values displayed are okay, while in H9 Channel 90, wiggle the harness, the foot throttle connector X-324 and the controller connectors X-450 and X-460 to check for an intermittent circuit. Channel 90 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the hand throttle connector X-324 and the controller connectors X-450 and X-460. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for 5 Volts. A. Disconnect connector X-324. Turn the ignition key switch ON. Measure the voltage between connector X-324 pin 4, wire 228 (TQ) and ground. If the voltage indicated is not approximately 5 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately 5 Volts, continue to step 4 4. Check for an open circuit ground circuit. A. Turn the ignition key switch OFF. Disconnect controller connector X-450.. Check between connector X-324 pin 3 and X-450 pin 12, wire 231 (BK/WH) and ground. If an open circuit is indicated, repair or replace the harness as required B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Check between connector X-450 pin 8 and X-324 pin 2, wire 226 (RD). If an open circuit is indicated, repair or replace the harness as required B. If an open circuit is not indicated, continue to step 6 6. Check for a short to Ve Voltage. A. Turn the ignition key switch ON. Measure the voltage between connector X-324 pin 2, wire 226 (RD) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the hand throttle, If the fault is still present, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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Electrical systems - FAULT CODES

3127-Hand throttle - signal 1 too low Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty hand throttle sensor 3. Faulty harness 4. Faulty controller Solution: 1. Check the hand throttle potentiometer in H9 Channel 90. A. Operate the hand throttle. If the values displayed do not change continuously between 200 - 4800 mV , continue to step 2 B. If the values displayed are okay, while in H9 Channel 90, wiggle the harness, the hand throttle connector X-324 and the controller connectors X-450 and X-460 to check for an intermittent circuit. Channel 90 values will change if an intermittent circuit is detected, repair or replace as required. 2. Check the hand throttle connector X-324 and the controller connectors X-450 and X-460. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for 5 Volts. A. Disconnect connector X-324. Turn the ignition key switch ON. Measure the voltage between connector X-324 pin 4, wire 228 (TQ) and ground. If the voltage indicated is not approximately 5 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately 5 Volts, continue to step 4 4. Check for an open circuit ground circuit. A. Turn the ignition key switch OFF. Disconnect controller connector X-450.. Check between connector X-324 pin 3 and X-450 pin 12, wire 231 (BK/WH) and ground. If an open circuit is indicated, repair or replace the harness as required B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Check between connector X-450 pin 8 and X-324 pin 2, wire 226 (RD). If an open circuit is indicated, repair or replace the harness as required B. If an open circuit is not indicated, continue to step 6 6. Check for a short to ground. A. Check between connector X-324 pin 2, wire 226 (RD) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the hand throttle, If the fault is still present, download the correct level of software. If the fault re-occurs, remove and replace the controller.

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Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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3137-High pressure pump solenoid valve - open circuit Control Module : ECU Context: The engine control unit (ECU) has determined that an open circuit condition exists in the Pump control valve (Metering Unit - High Pressure Pump Regulator solenoid/valve) circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common rail. The metering unit is controlled by both main relay 1 high side and a low side power stages (Main Relay 1 is an electronic control circuit within the ECU used to provide fixed and variable control signals to devices external to the ECU). The monitoring at low side is stopped if a short circuit to ground at the high side (main relay 1) is detected or it is switched off for some reason. Failure detection of an over current condition is only possible if the low side power stage is switched on and the open circuit condition only if it is switched off. With the current settings, the monitoring is shut off during after-run. This error is the result of the power stage hardware report of an 'open load' in the metering unit longer than 200 milliseconds. Cause: Pump control valve circuit is open. Possible failure modes: 1. Faulty Pump control valve, open solenoid coil. 2. Faulty circuit, open conductor. 3. Faulty ECU, hardware or software. Solution: 1. Disconnect the ECU cylinder connector from the ECU at connector X-939. Use a multi-meter to check the resistance on the Engine Injector harness side of connector X-939 from pin 15, wire 400 (BR/GN) to pin 60, wire 424 (GY/WH). There should be approximately 3.2 立. A. If there is approximately 3.2 立, check for other ECU errors that could inhibit operation of the ECU main relay 1 circuit and follow those troubleshooting procedures. B. If there is a high resistance reading, leave connector X-939 disconnected and continue with step 2 2. Disconnect the Engine Injector harness from the Pump control valve at connector X-970. Use a multi-meter to check the resistance of the Pump control valve solenoid coil. There should be approximately 3.2 立. A. If there is approximately 3.2 立, leave connector X-970 disconnected and continue with step 3 B. If there is a high resistance reading, replace the Pump control valve solenoid. 3. Use a multi-meter to check for continuity from the Engine Injector harness side of connector X-970 pin 1, to the Engine Injector harness side of connector X-939 pin 15, wire 400 (BR/GN). There should be continuity. A. If there is continuity, leave the connectors disconnected and continue with step 4 B. If there is no continuity, locate and repair the break in the wire. 4. Use a multi-meter to check for continuity from the Engine Injector harness side of connector X-970 pin 2 to the Engine Injector harness side of connector X-939 pin 60, wire 424 (GY/WH). There should be continuity. A. If there is continuity, try reloading the ECU software and if the error reoccurs, replace the ECU. B. If there is no continuity, locate and repair the break in the wire.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3139-High pressure pump solenoid valve - signal too high Control Module : ECU Context: The engine control unit (ECU) has determined that it is sensing a voltage greater than 5.2 V. The metering unit of the fuel high pressure pump regulates the pressure in the common rail. Cause: Fuel high pressure pump circuit is shorted to a high source. Possible failure modes: 1. Faulty fuel high pressure pump control circuit, shorted to a high source. 2. Faulty fuel high pressure pump 3. Faulty ECU, hardware or software. Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Disconnect the wiring harness from the ECU connector X-939. Place the Key switch in the "On" position. Use a multi-meter to test for voltage from the wiring harness side connector X-939 pin 41, wire 413 (RD/GN) to chassis ground. There should be no voltage. A. If there is voltage, locate and repair the short to the voltage source. B. If there is no voltage, continue with step 3 3. Disconnect the wiring harness from the fuel high pressure pump X-970 . Use a multi-meter to check the resistance of the fuel high pressure pump solenoid coil. There should be a small amount of resistance. A. If there is a small amount of resistance, try reloading the ECU software and if the error reoccurs, replace the ECU. B. If there is no resistance, the fuel high pressure pump solenoid coil has failed, replace the solenoid.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3140-High pressure pump solenoid valve - signal too low Control Module : ECU Context: The engine control unit (ECU) has determined that the sensing voltage is too low. The metering unit of the fuel high pressure pump regulates the pressure in the common rail. Cause: Fuel high pressure pump circuit is shorted to a low source. Possible failure modes: 1. Fuel high pressure pump control circuit, shorted to a low source. 2. Faulty Fuel high pressure pump 3. Faulty control module. Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Disconnect the wiring harness from the ECU module connector X-939. Use a multi-meter to check for continuity from the wiring harness side of ECU connector X-939 pin 41, wire 413 (RD/GN) chassis ground. There should be no continuity. A. If there is continuity, continue with step 3 B. If there is no continuity, try reloading the ECU software and if the error reoccurs, replace the ECU. 3. Disconnect the wiring harness from the Fuel high pressure pump connector X-970. Use a multi-meter to check for continuity on the fuel high pressure pump connector pins 1 and 2 to chassis ground. There should be no continuity on either pin to ground. A. If there is continuity on either pin, the fuel high pressure pump solenoid coil has failed, replace the solenoid. B. If there is no continuity on either pin, there is a short to low source in the wiring harness, locate and repair the short to ground.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3146-Water in fuel sensor - water detected or faulty sensor Control Module : ECU Context: The Water in fuel detection is carried out with a digital sensor located in the fuel filter. Cause: The Engine Control Unit (ECU) has determined that there is either water in the fuel or a fault associated with the water in fuel sensor has occurred. Possible failure modes: 1. Water in fuel 2. Faulty connector 3. Faulty harness 4. Faulty water in fuel sensor Solution: 1. Drain the fuel filter of water and verify this error code is still present and in an active state. A. If the error is still present and active, continue to step 2 B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Check the water in fuel sensor connector X-450, the ECU connector X-937 and the engine ground connector X-420 A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for 12 Volts. A. Disconnect connector X-950. Turn the key switch ON. Measure the voltage between connector X-950 pin 3, wire 345 (OR) and ground. If the voltage indicated is not approximately 12 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately 12 Volts, continue to step 4 4. Check for an open ground circuit. A. Turn the key switch OFF. Check between connector X-950 pin 2, wire 335 (BK) and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Disconnect the controller connector X-937. Check between connector X-950 pin 1, wire 347 (YE) and X-937 pin 30, wire 347 (YE). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 6 6. Check for a short to ground. A. Check between connector X-937 pin 1, wire 347 (YE) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the water in fuel sensor.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3157-CAN-Bus - ECU absent or engine dataset not available Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. NOTE: The message to 'register the dataset, if it has been changed', will occasionally appear on the EST after downloading software. If the procedure to register the dataset has been completed, the machine needs to run for five minutes to complete the registration process between machine modules. Cause: Engine controller configuration took longer than 4 minutes or the engine control unit (ECU) was not detected on the CAN BUS.

Possible failure modes: 1. ECU configuration timed out 2. ECU not detected on the CAN BUS Solution: 1. Make sure the configuration process was started within the 4 minute time out period. Erase fault and proceed with configuration. Download the correct engine data set using the electronic service tool (EST) easy engine download tool. After download, register the engine data set for use with the EST configuration screen â&#x20AC;&#x153;Engine data registration.â&#x20AC;? A. If the error code is 3157 not indicated, check that the system is operating correctly. B. If the error code 3157 is still indicated, continue to step 2 2. Check for other CAN BUS related error codes being displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check all power supplies and grounds to the engine controller at connector X-937. A. If a fault is indicated, repair or replace the harness as required. B. If no faults are indicated, download the correct level of software to the XCM. If the fault is still present, download the correct level of software to the instrument cluster.

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Electrical systems - FAULT CODES

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3166-Fuel heater relay - short circuit to battery Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty connector 2. Faulty fuel filter heater relay 3. Faulty harness 4. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check the ECU connector X-937 and the fuel filter heater relay connector X-110. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the fuel filter heater relay. A. Remove the fuel filter heater relay and check the operation of the relay. If the relay does not operate correctly, replace the fuel filter heater relay. B. If the relay is okay, continue to step 4 4. Check for a short to Ve voltage A. Disconnect the ECU connector X-937. Check between connector: X-937 pin 70, wire 1249 (GN) and ground If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the ECU.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3167-Fuel heater relay - short circuit to ground Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty connector 2. Faulty fuel filter heater relay 3. Faulty harness 4. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check the ECU connector X-937 and the fuel filter heater relay connector X-110. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the fuel filter heater relay. A. Remove the fuel filter heater relay and check the operation of the relay. If the relay does not operate correctly, replace the fuel filter heater relay. B. If the relay is okay, continue to step 4 4. Check for a short to ground. A. Disconnect the ECU connector X-937 and the fuel filter heater relay connector X-110. Check between connector: X-937 pin 70, wire 1249 (GN) and ground X-110 pin R3_86 (BR) and ground If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the ECU.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3168-Fuel heater relay - open circuit Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty connector 2. Faulty fuel filter heater relay 3. Faulty harness 4. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check the ECU connector X-937 and the fuel filter heater relay connector X-110. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the fuel filter heater relay. A. Remove the fuel filter heater relay and check the operation of the relay. If the relay does not operate correctly, replace the fuel filter heater relay. B. If the relay is okay, continue to step 4 4. Check for an open circuit. A. Disconnect the ECU connector X-937 and the fuel filter heater relay connector X-110. Check between connector: X-937 pin 70, wire 1249 (GN) and X-110 pin R3_85, wire 1248 (BK/YE) X-110 pin R3_86, wire 1289 (BR) and X-110 pin 35A, wire 712 (BR) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the fuel filter heater.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3169-Fuel heater relay - signal not plausible Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: Possible failure modes: 1. Faulty connector 2. Faulty fuel filter heater relay 3. Faulty harness 4. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check the ECU connector X-937 and the fuel filter heater relay connector X-110. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the fuel filter heater relay. A. Remove the fuel filter heater relay and check the operation of the relay. If the relay does not operate correctly, replace the fuel filter heater relay. B. If the relay is okay, continue to step 4 4. Check for an open circuit. A. Disconnect the ECU connector X-937 and fuel heater relay connector X-110. Check between connector: X-937 pin 70, wire 1249 (GN) and X-110 pin R3_85, wire 1248 (BK/YE) X-110 pin R3_86, wire 1289 (BR) and X-110 pin 35A, wire 712 (BR) . If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault re-occurs, remove and replace the ECU.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3179-CAN-Bus message timeout - BC2EDC2 from ADIC Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: The ECU has detected a timeout of BCM2EDC CAN message. Possible failure modes: 1. Faulty harness 2. CAN BUS interference 3. Faulty ECU 4. Faulty central control unit ( CCU) Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the tractor under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other CAN related error codes displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check all power supplies and grounds to the controllers on the CAN BUS network. A. If a fault is indicated, repair or replace the harness as required. B. If the power supplies and grounds are okay, download the correct levels of controller software. If the fault is still present, remove and replace the ECU.

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Electrical systems - FAULT CODES

Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

14 15 17 18

(55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15) (55.100.DP-C.20.E.17) (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3180-CAN-Bus message timeout - VCM2EDC from ADIC Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: The ECU has detected a timeout of VCM2EDC CAN message. Possible failure modes: 1. Faulty harness 2. CAN BUS interference 3. Faulty ECU 4. Faulty central control unit ( CCU) Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the tractor under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other CAN related error codes displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check all power supplies and grounds to the controllers on the CAN BUS network. A. If a fault is indicated, repair or replace the harness as required. B. If the power supplies and grounds are okay, download the correct levels of controller software. If the fault is still present, remove and replace the ECU.

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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

14 15 17 18

(55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15) (55.100.DP-C.20.E.17) (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3188-Injector cylinder 1 - open circuit Control Module : ECU Context: The Engine control unit (ECU) has determined that an open circuit condition exists in the Cylinder 1 injector circuit. A power stage component energizes the unit injection system transistors and simultaneously observes the current flow in the high-side and low-side switching branch by sensing resistors. If there is a deviation from the expected current flow the component detects specific errors and reports them to the ECU. This error message is then rearranged so it holds information on performed injections, errors of cylinders on the same bank, bank specific errors and cylinder specific errors. The rearranged error message is then compared to applicable error patterns and if there is a match the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of an open circuit failure being present for over 3 camshaft revolutions. As a result of this error an individual cylinder or bank is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent (without a healing possibility, once tested by switching on the component to see if the defect is still present) and others evoke an irreversible or reversible shut off of the engine to be executed. Cause: The Engine control unit (ECU) has determined that there is a fault associated with the current monitoring of the Cylinder 1 injector output power driver stage. Possible failure modes: 1. Faulty Cylinder 1 injector solenoid windings. 2. Faulty electrical wiring, open circuit (damaged wiring). 3. Faulty ECU, hardware or software. Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Carefully disconnect the engine harness from the ECU at the cylinder connector, X-939. Use a multi-meter to check the resistance, on the engine harness side of the cylinder connector X-939, between pin 16, wire 429 (TQ/ WH) and pin 32, wire 432 (WH/OR). There should be 0.4 - 0.5 ÎŠ. A. If the resistance is within range, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs, replace the ECU . B. If the resistance was significantly greater than maximum range, continue with step 3 3. Disconnect the engine cylinder harness from the injector (valve) cover at connector X-940. Use a multi-meter to check resistance on the injector (valve) cover side of connector X-940 from pin A to pin B. There should be 0.4 0.5 ÎŠ. A. If a small amount of resistance exists, there is open circuit condition in the engine cylinder harness between the ECU cylinder harness connector X-939 and the Cylinder valve cover connector X-940. Locate and repair the broken conductor. B. If the resistance was significantly greater than maximum range, continue with step 4 4. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 1 injector at connector X-951. Use a multi-meter to check resistance, on the Cylinder 1 injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 ÎŠ. A. If the resistance is within range, there is an open circuit condition in the injector harness, between injector connector X-951 and ECU cylinder connector X-940. Locate and repair the broken conductor.

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B. If the resistance was significantly greater than maximum range, the Cylinder 1 injector solenoid coil has failed. Replace the injector.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3192-Injector cylinder 2 - open circuit Control Module : ECU Context: The engine control unit (ECU) has determined that an open circuit condition exists in the Cylinder 2 injector circuit. A power stage component energizes the unit injection system transistors and simultaneously observes the current flow in the high-side and low-side switching branch by sensing resistors. If there is a deviation from the expected current flow the component detects specific errors and reports them to the ECU. This error message is then rearranged so it holds information on performed injections, errors of cylinders on the same bank, bank specific errors and cylinder specific errors. The rearranged error message is then compared to applicable error patterns and if there is a match the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of an open circuit failure being present for over 3 camshaft revolutions. As a result of this error an individual cylinder or bank is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent (without a healing possibility, once tested by switching on the component to see if the defect is still present). and others evoke an irreversible or reversible shut off of the engine to be executed. Cause: The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the Cylinder 2 injector output power driver stage. Possible failure modes: 1. Faulty injection valve or open solenoid windings. 2. Faulty electrical wiring, open circuit (damaged wiring). 3. Faulty ECU, hardware or software. Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Carefully disconnect the engine injector harness from the ECU at connector X-939 . Use a multi-meter to check the resistance, on the engine injector harness side of connector X-939, between pin 46, wire 433 (YE/BK) and pin 2, wire 428 (TQ/GN). There should be 0.4 - 0.5 ÎŠ. A. If the resistance is within range, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs, replace the ECU. B. If the resistance was significantly greater than maximum range, continue with step 3 3. Disconnect the engine injector harness from the injector (valve) cover at connector X-940. Use a multi-meter to check resistance on the injector (valve) cover side of connector X-940 from pin G to pin H. There should be 0.4 0.5 ÎŠ. A. If a small amount of resistance exists, there is open circuit condition in the engine injector harness between connector X-939 and connector X-940. Locate and repair the broken conductor. B. If the resistance was significantly greater than maximum range, continue with step 4 4. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 2 injector at connector X-952 terminal 1. Use a multi-meter to check resistance, on the Cylinder 2 injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 ÎŠ. A. If the resistance is within range, there is an open circuit condition in the injector harness, between connector X-940 and connector X-952. Locate and repair the broken conductor.

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B. If the resistance was significantly greater than maximum range, the Cylinder 2 injector solenoid coil has failed. Replace the injector.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3196-Injector cylinder 3 - open circuit Control Module : ECU Context: The engine control unit (ECU) has determined that an open circuit condition exists in the Cylinder 3 injector circuit. A power stage component energizes the unit injection system transistors and simultaneously observes the current flow in the high-side and low-side switching branch by sensing resistors. If there is a deviation from the expected current flow the component detects specific errors and reports them to the ECU. This error message is then rearranged so it holds information on performed injections, errors of cylinders on the same bank, bank specific errors and cylinder specific errors. The rearranged error message is then compared to applicable error patterns and if there is a match the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of an open circuit failure being present for over 3 camshaft revolutions. As a result of this error an individual cylinder or bank is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent (without a healing possibility, once tested by switching on the component to see if the defect is still present). and others evoke an irreversible or reversible shut off of the engine to be executed. Cause: The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the Cylinder 3 injector output power driver stage. Possible failure modes: 1. Faulty injection valve or open solenoid windings. 2. Faulty electrical wiring, open circuit (damaged wiring). 3. Faulty ECU, hardware or software. Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Carefully disconnect the engine injector harness from the ECU at connector X-939. Use a multi-meter to check the resistance, on the engine injector harness side of connector X-939, between pin 31, wire 431 (WH) and pin 1, wire 427 (TQ/BK). There should be 0.4 - 0.5 ÎŠ. A. If the resistance is within range, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs, replace the ECU. B. If the resistance was significantly greater than maximum range, continue with step 3 3. Disconnect the engine injector harness from the injector (valve) cover at connector X-940. Use a multi-meter to check resistance on the injector (valve) cover side of connector X-940 from pin C to pin D. There should be 0.4 0.5 ÎŠ. A. If a small amount of resistance exists, there is open circuit condition in the engine injector harness between connector X-939 and connector X-940. Locate and repair the broken conductor. B. If the resistance was significantly greater than maximum range, continue with step 4 4. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 3 injector at connector X-953 Use a multi-meter to check resistance, on the Cylinder 3 injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 ÎŠ. A. If the resistance is within range, there is an open circuit condition in the injector harness, between connector X-953 and connector X-940. Locate and repair the broken conductor.

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B. If the resistance was significantly greater than maximum range, the Cylinder 3 injector solenoid coil has failed. Replace the injector.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3200-Injector cylinder 4 - open circuit Control Module : ECU Context: The engine control unit (ECU) has determined that an open circuit condition exists in the Cylinder 4 injector circuit. A power stage component energizes the unit injection system transistors and simultaneously observes the current flow in the high-side and low-side switching branch by sensing resistors. If there is a deviation from the expected current flow the component detects specific errors and reports them to the ECU. This error message is then rearranged so it holds information on performed injections, errors of cylinders on the same bank, bank specific errors and cylinder specific errors. The rearranged error message is then compared to applicable error patterns and if there is a match the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of an open circuit failure being present for over 3 camshaft revolutions. As a result of this error an individual cylinder or bank is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent (without a healing possibility, once tested by switching on the component to see if the defect is still present). and others evoke an irreversible or reversible shut off of the engine to be executed. Cause: The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the Cylinder 4 injector output power driver stage. Possible failure modes: 1. Faulty injection valve or open solenoid windings. 2. Faulty electrical wiring, open circuit (damaged wiring). 3. Faulty ECU, hardware or software. Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Carefully disconnect the engine injector harness from the ECU at connector X-939. Use a multi-meter to check the resistance, on the engine injector harness side of connector X-939, between pin 17, wire 430 (TQ/YE) and pin 48, wire 434 (YE/RD). There should be 0.4 - 0.5 ÎŠ. A. If the resistance is within range, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs, replace the ECU. B. If the resistance was significantly greater than maximum range, continue with step 3 3. Disconnect the engine injector harness from the injector (valve) cover at connector X-940. Use a multi-meter to check resistance on the injector (valve) cover side of connector X-940 from pin E to pin F. There should be 0.4 0.5 ÎŠ. A. If a small amount of resistance exists, there is open circuit condition in the engine injector harness between connector X-939 and connector X-940. Locate and repair the broken conductor. B. If the resistance was significantly greater than maximum range, continue with step 4 4. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 4 injector at connector X-954. Use a multi-meter to check resistance, on the Cylinder 4 injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 ÎŠ. A. If the resistance is within range, there is an open circuit condition in the injector harness, between connector X-940 and connector X-954. Locate and repair the broken conductor.

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B. If the resistance was significantly greater than maximum range, the Cylinder 4 injector solenoid coil has failed. Replace the injector.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3210-Injection bank 1 - short circuit on injection cable Control Module : ECU NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to accurately measure resistance . The DMM must measure to a resolution of 0.1 ohms. The required measurements are as low as 0.4 ohms (typical injector solenoid coil resistance is 0.4 - 0.5 ÎŠ) and any DMM inaccuracies will cause the technician to inaccurately troubleshoot. NOTE: Ensure the DMM's test lead resistance is considered when measuring resistance. Touch the leads together on the lowest Ohms scale and record the resistance measurement. Subtract this value from all future resistance measurements. Context: The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 1. A power stage component energizes the injection system transistors while observing the current flow in the high-side and low-side switching branch by sensing resistors. Deviations from the expected current flow are detected as specific errors by the component and reported to the ECU. Error messages are configured to contain information on performed injections, same bank cylinder errors, bank specific errors and cylinder specific errors. The configured error message is compared to applicable error patterns, and the failure matching the pattern is output. If an error message doesn't match a pattern the defect becomes an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is a result of a general short circuit of the high side to battery or ground over 4 camshaft revolutions. This error shuts off an individual cylinder or bank, based on ECU parameters. Certain parameters, as currently applied, are permanent; there is no healing possibility after testing: switching on the component to ascertain the defect's presence. Others evoke an irreversible or reversible engine shut off. Cause: The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of an injector output power driver stage in Bank 1. Possible failure modes: 1. Faulty injection valve or shorted solenoid windings. 2. Faulty electrical wiring, short high side to high source, low side or ground (damaged wiring harness). 3. Faulty ECU, hardware or software. Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Disconnect the engine injector harness from the ECU at connector X-939. Use a DMM to check the resistance on the engine injector harness side of connector X-939 From: 1. Pin 16, wire 429 (TQ/WH) to pin 32, wire 432 (WH/OR) 2. Pin 46, wire 433 (YE/BK) to pin 2, wire 428 (TQ/GN) 3. Pin 31, wire 431 (WH) to pin 1, wire 427 (TQ/BK) 4. Pin 17, wire 430 (TQ/YE) to pin 48, wire 434 (YE/RD) There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, leave ECU connector X-939 disconnected and continue to step 8. B. If the resistance was below range, record the pin numbers and continue to step 3. 3. Use a DMM to check for continuity on the engine injector harness side of connector X-939, from pins 1, 2, 16 and 17 to chassis ground. There should not be continuity. 47538922 29/05/2013

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A. If there was continuity, record the pin number and continue to step 4. B. If there was no continuity, continue to step 6. 4. Disconnect the engine injector harness from the injector (valve) cover at connector X-940. Use a DMM to check for continuity on the injector (valve) cover side of connector : From: 1. Connector X-940 pin A, if recorded pin in Step 3 was pin 16, to chassis ground 2. Connector X-940 pin H, if recorded pin in Step 3 was pin 2, to chassis ground 3. Connector X-940 pin D, if recorded pin in Step 3 was pin 1, to chassis ground. 4. Connector X-940 pin E, if recorded pin in Step 3 was pin 17, to chassis ground. There should not be continuity. A. If there was continuity, leave connector X-940 disconnected. Continue to step 5. B. If there was no continuity, there is a short to ground condition in the engine injector harness between connector X-940 pin A, D, E or H, and ECU connector X-939 pin 1, 2, 16 or 17. Locate and repair the grounded conductor. 5. Remove the injector (valve) cover and disconnect the injector harness from the injector: For: 1. Cylinder #1 injector at connector X-951 if recorded pin in Step 3 was pin 16 2. Cylinder #2 injector at connector X-952 if recorded pin in Step 3 was pin 2 3. Cylinder #3 injector at connector X-953 if recorded pin in Step 3 was pin 1 4. Cylinder #4 injector at connector X-954 if recorded pin in Step 3 was pin 17 Use a DMM to check for continuity, on the injector, from terminal 1 to chassis ground. There should not be continuity. A. If there is continuity, the injector solenoid coil has failed: replace the injector. B. If there is no continuity, there is a short to ground condition in the injector circuit, between connector X-951 (if recorded pin in Step 3 was pin 16), or connector X-952 (if recorded pin in Step 3 was pin 2), or connector X-953 (if recorded pin in Step 3 was pin 1), or connector X-954 (if recorded pin in Step 3 was pin 17) and connector X-940 pin A, D, E or H and ECU connector X-939 pin 1, 2, 16 or 17 Locate and repair the grounded conductor. 6. Disconnect the engine injector harness from the injector cover at connector X-940. Use a DMM to measure the resistance on the injector cover side of connector : From: 1. X-940 pin A to B, if recorded pins in Step 2 were pins 16 and 32 2. X-940 pin C to D, if recorded pins in Step 2 were pins 31 and 1 3. X-940 Pin E to F, if recorded pins in Step 2 were pins 17 and 48 4. X-940 Pin G to H, if recorded pins in Step 2 were pins 46 and 2 There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, there is a short circuit condition in the engine injector harness between connector X-940 pin B, C, F, or G, and ECU connector X-939 pin 31, 32, 46, or 48. Locate and repair the short circuit. B. If the resistance was below range, continue to step 7 7. Remove the injector (valve) cover and disconnect the injector harness from the injector:

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For: 1. Cylinder #1 injector at connector X-951, if recorded pins in Step 2 were pins 16 and 32 2. Cylinder #2 injector at connector X-952, if recorded pins in Step 2 were pins 2 and 46 3. Cylinder #3 injector at connector X-953, if recorded pins in Step 2 were pins 1 and 31 4. Cylinder #4 injector at connector X-954, if recorded pins in Step 2 were pins 17 and 48 Use a DMM to check for continuity, on the injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, there is a short circuit condition in the injector harness, between connector X-951, or X-952, or X-953, or X-954 and connector X-940 pin B, C, F, or G and ECU connector X-939 pin 31, 32, 46, or 48. Locate and repair the shorted conductors. B. If the resistance was below range, the injector solenoid coil has failed. Replace the injector. 8. Use a DMM to check for continuity, on the engine injector harness side of ECU connector X-939, from pins 1, 2, 16 and 17 to all other populated pins in connector X-939. There should not be continuity. A. If there is continuity, record the pin numbers and use to locate and repair the shorted conductors. B. If there is no continuity, the ECU may have failed. Attempt reloading the ECU software. If the fault reoccurs, replace the ECU.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3218-Injection bank 2 - short circuit on injection cable Control Module : ECU NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to accurately measure resistance . The DMM must measure to a resolution of 0.1 ohms. The required measurements are as low as 0.4 ohms (typical injector solenoid coil resistance is 0.4 - 0.5 ÎŠ) and any DMM inaccuracies will cause the technician to inaccurately troubleshoot. NOTE: Ensure the DMM's test lead resistance is considered when measuring resistance. Touch the leads together on the lowest Ohms scale and record the resistance measurement. Subtract this value from all future resistance measurements. Context: The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 2. A power stage component energizes the injection system transistors while observing the current flow in the high-side and low-side switching branch by sensing resistors. Deviations from the expected current flow are detected as specific errors by the component and reported to the ECU. Error messages are configured to contain information on performed injections, same bank cylinder errors, bank specific errors and cylinder specific errors. The configured error message is compared to applicable error patterns, and the failure matching the pattern is output. If an error message doesn't match a pattern the defect becomes an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is a result of a general short circuit of the high side to battery or ground over 4 camshaft revolutions. This error shuts off an individual cylinder or bank, based on ECU parameters. Certain parameters, as currently applied, are permanent; there is no healing possibility after testing: switching on the component to ascertain the defect's presence. Others evoke an irreversible or reversible engine shut off. Cause: The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of an injector output power driver stage in Bank 2. Possible failure modes: 1. Faulty injection valve or shorted solenoid windings. 2. Faulty electrical wiring, short high side to high source, low side or ground (damaged wiring harness). 3. Faulty ECU, hardware or software. Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Disconnect the engine injector harness from the ECU at connector X-939. Use a DMM to check the resistance on the engine injector harness side of connector X-939 From: 1. Pin 16, wire 429 (TQ/WH) to pin 32, wire 432 (WH/OR) 2. Pin 46, wire 433 (YE/BK) to pin 2, wire 428 (TQ/GN) 3. Pin 31, wire 431 (WH) to pin 1, wire 427 (TQ/BK) 4. Pin 17, wire 430 (TQ/YE) to pin 48, wire 434 (YE/RD) There should be 0.4 - 0.5 ÎŠ. A. If the resistance was within range, leave ECU connector X-939 disconnected and continue to step 8. B. If the resistance was below range, record the pin numbers and continue to step 3. 3. Use a DMM to check for continuity on the engine injector harness side of connector X-939, from pins 1, 2, 16 and 17 to chassis ground. There should not be continuity. 47538922 29/05/2013

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3283-Sensor supply voltage 2 - voltage out of valid range Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. NOTE: Check alternator output voltage. Troubleshoot charging system before proceeding. Cause: Besides the 3 independent 5 V voltage supplies the ECU also provides a 12 V supply for the sensors. This 12 V supply is monitored to ensure it remains within a certain range. This is done by using an analog input of the ECU. The lower and upper thresholds depend on the battery voltage. Possible failure modes: 1. Faulty wiring. 2. Faulty connectors 3. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the fault is still present, continue to step 2 2. Check for other engine sensor related error codes. A. If other engine sensor related error codes are displayed, continue to these tests. B. If no other engine sensor related error codes are displayed, continue to step 3 3. Check for 12 V A. Turn the ignition key switch ON. Measure the voltage between connector X-937 pin 1, wire 31 (RD/BK) and ground X-937 pin 3, wire 30 (RD/YE) and ground X-937 pin 5, wire 29 (RD/YE) and ground X-937 pin 28, wire 28 (BK/WH) and ground If the voltage indicated is not approximately 12 Volts, repair or replace the harness as required. B. If the ECU supply voltage is okay, download the correct level of software. If the fault re-occurs, remove and replace the ECU

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3285-Sensor supply voltage 3 - voltage out of valid range Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. NOTE: Check alternator output voltage. Troubleshoot charging system before proceeding. Cause: Besides the 3 independent 5 V voltage supplies the ECU also provides a 12 V supply for the sensors. This 12 V supply is monitored to ensure it remains within a certain range. This is done by using an analog input of the ECU. The lower and upper thresholds depend on the battery voltage. Possible failure modes: 1. Faulty wiring. 2. Faulty connectors 3. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the fault is still present, continue to step 2 2. Check for other engine sensor related error codes. A. If other engine sensor related error codes are displayed, continue to these tests. B. If no other engine sensor related error codes are displayed, continue to step 3 3. Check for 12 V A. Turn the ignition key switch ON. Measure the voltage between connector X-937 pin 1, wire 31 (RD/BK) and ground X-937 pin 3, wire 30 (RD/YE) and ground X-937 pin 5, wire 29 (RD/YE) and ground X-937 pin 28, wire 28 (BK/WH) and ground If the voltage indicated is not approximately 12 Volts, repair or replace the harness as required. B. If the ECU supply voltage is okay, download the correct level of software. If the fault re-occurs, remove and replace the ECU.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3301-High pressure pump solenoid valve - maximum negative rail pressure deviation exceeded Control Module : ECU Context: The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too high with a closed Metering Unit (High Pressure Pump Regulator - solenoid valve). The rail pressure is monitored by various fault paths during active pressure control by the metering unit. The fault path at hand detects an excessive negative rail pressure governor deviation (too high rail pressure) at zero delivery of fuel volume flow through the metering unit. The monitoring is only active if the high pressure governor is operating in closed loop control, the engine is not in overrun, the fuel system temperature is above 24.96 Â°C (76.9 Â°F), the current injection quantity is above 0.0 g (0.00 oz) per cycle and the monitoring has not been inhibited by other faults. Cause: Possible failure modes: 1. Faulty high pressure pump regulator (fuel metering unit) X-970, stuck open. 2. Pressure too high, low pressure side. Solution: 1. Check for high pressure pump regulator (fuel metering unit) errors. A. If high pressure pump regulator (fuel metering unit) errors exist, follow troubleshooting procedure for existing high pressure pump regulator (solenoid/valve) error. B. If no high pressure pump regulator (fuel metering unit) errors exist, locate and repair high pressure condition in low pressure side of fuel system.

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3309-High pressure pump solenoid valve - maximum rail pressure exceeded Control Module : ECU Context: The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too high. The rail pressure is monitored by various fault paths during active pressure control by the metering unit. The fault path at hand detects if the rail pressure has exceeded a maximum pressure threshold. The monitoring is only active if the high pressure governor is operating in closed loop control and the monitoring has not been inhibited by other faults. If the rail pressure exceeds the maximum pressure 170 bar (2465.0 psi) over 1 second, this error will occur. Cause: The Fuel Rail/System Pressure is too high. Possible failure modes: 1. Faulty high pressure pump regulator (fuel metering unit) X-970, stuck open. 2. Pressure too high, low pressure side. Solution: 1. Check for high pressure pump regulator (fuel metering unit) errors. A. If high pressure pump regulator (fuel metering unit) errors exist, follow troubleshooting procedure for existing high pressure pump regulator (fuel metering unit) error. B. If no high pressure pump regulator (fuel metering unit) errors exist, locate and repair high pressure condition in low pressure side of fuel system.

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Electrical systems - FAULT CODES

3334-CAN-Bus message timeout - TSC1-PE from CCU (when active) Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: The CAN message TSC1PE contains the information for torque/speed demand from the vehicle controller (XCM) to the engine control unit (ECU). The ECU has detected a timeout of TSC1_PE message. Possible failure modes: 1. Faulty harness 2. CAN BUS interference 3. Faulty ECU 4. Faulty central control unit ( CCU) Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the tractor under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other CAN related error codes displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check all power supplies and grounds to the controllers on the CAN BUS network. A. If a fault is indicated, repair or replace the harness as required. B. If the power supplies and grounds are okay, download the correct levels of controller software. If the fault is still present, remove and replace the ECU.

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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

14 15 17 18

(55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15) (55.100.DP-C.20.E.17) (55.100.DP-C.20.E.18)

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3335-CAN-Bus message timeout - TSC1-PE from CCU (when inactive) Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: The CAN message TSC1PE contains the information for torque/speed demand from the vehicle controller (XCM) to the engine control unit (ECU). The ECU has detected a timeout of TSC1_PE message. Possible failure modes: 1. Faulty harness 2. CAN BUS interference 3. Faulty ECU 4. Faulty central control unit ( CCU) Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the tractor under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other CAN related error codes displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check all power supplies and grounds to the controllers on the CAN BUS network. A. If a fault is indicated, repair or replace the harness as required. B. If the power supplies and grounds are okay, download the correct levels of controller software. If the fault is still present, remove and replace the ECU.

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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

14 15 17 18

(55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15) (55.100.DP-C.20.E.17) (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3338-CAN-Bus message timeout - TSC1-VE from CCU (when inactive) Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: The CAN message TSC1VE contains the information for torque/speed demand from the vehicle controller (XCM) to the engine control unit (ECU). The ECU has detected a timeout of TSC1_VE message. Possible failure modes: 1. Faulty harness 2. CAN BUS interference 3. Faulty ECU 4. Faulty central control unit ( CCU) Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the tractor under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other CAN related error codes displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check all power supplies and grounds to the controllers on the CAN BUS network. A. If a fault is indicated, repair or replace the harness as required. B. If the power supplies and grounds are okay, download the correct levels of controller software. If the fault is still present, remove and replace the ECU.

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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

14 15 17 18

(55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15) (55.100.DP-C.20.E.17) (55.100.DP-C.20.E.18)

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3339-CAN-Bus message timeout - TSC1-VE from CCU (when active) Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: The CAN message TSC1VE contains the information for torque/speed demand from the vehicle controller (XCM) to the engine control unit (ECU). The ECU has detected a timeout of TSC1_VE message. Possible failure modes: 1. Faulty harness 2. CAN BUS interference 3. Faulty ECU 4. Faulty central control unit ( CCU) Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the tractor under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other CAN related error codes displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check all power supplies and grounds to the controllers on the CAN BUS network. A. If a fault is indicated, repair or replace the harness as required. B. If the power supplies and grounds are okay, download the correct levels of controller software. If the fault is still present, remove and replace the ECU.

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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

14 15 17 18

(55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15) (55.100.DP-C.20.E.17) (55.100.DP-C.20.E.18)

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3358-CAN-Bus message timeout - transmit EEC1 Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: The CAN message EEC1 contains the current torque information as well as engine speed and engine starter information. The ECU has detected a timeout of EEC1 message. Possible failure modes: 1. Faulty harness 2. CAN BUS interference 3. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the tractor under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other CAN related error codes displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check all power supplies and grounds to the controllers on the CAN BUS network. A. If a fault is indicated, repair or replace the harness as required. B. If the power supplies and grounds are okay, download the correct levels of controller software. If the fault is still present, remove and replace the ECU.

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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

14 15 17 18

(55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15) (55.100.DP-C.20.E.17) (55.100.DP-C.20.E.18)

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3375-Constant engine speed increase/decrease switch - signals not plausible Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty constant engine speed (CRPM) increase/decrease switch 4. Faulty analog digital instrument cluster ( ADIC) Solution: 1. Check the constant engine speed (CRPM) increase/decrease switch connector X-369 and the controller connector X-450. A. Ensure the connectors are connected, not damaged, the pins the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 2 2. Check the constant engine speed (CRPM) increase/decrease switch in H5. A. Turn the ignition key switch ON. Depress the constant engine speed (CRPM) increase switch, d115 should be displayed, if the display does not change to d115, continue to step 3 B. Depress the constant engine speed (CRPM) decrease switch, d116 should be displayed, if the display does not change to d116, continue to step 4 C. If the display does change to d115 and d116, while still in H5 and depressing the buttons, wiggle the harness and the onstant engine speed (CRPM) increase/decrease connector X-369 to check for an intermittent circuit, repair or replace as required. 3. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connectors X-369 and X-450. Check between connector X-369 pin 3 (OR/BL) and X-450 pin 15 (OR/BL). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 4. Check for an open circuit. A. Turn the ignition key switch OFF. Disconnect connectors X-369 and X-450. Check between connector X-369 pin 1 (OR/WH) and X-450 pin 16 (OR/WH). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for a short circuit. A. Check between connector X-369 pin 1 (OR/WH) and X-369 pin 3 (OR/BL). If a short circuit is indicated, repair or replace the harness as required. B. If a short circuit is not indicated, continue to step 6 6. Check for 12 V. A. Turn the ignition key switch ON. Check between connector X-369 pin 2 (OR) and ground. If approximately 12 V is not indicated, repair or replace the harness as required to fuse F-020 (5 Amp). 47538922 29/05/2013

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B. If the harness is okay, replace the constant engine speed (CRPM) increase/decrease switch and test the system for normal operation. If the fault occurs again, replace the analog digital instrument cluster ( ADIC).

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3377-CRPM switches present but function not enabled Control Module : ECU Cause: The constant RPM (CRPM) option has not been configured, the analog digital instrument cluster ( ADIC) detects the CRPM switches via the wire. Possible failure modes: 1. Constant engine RPM switch option not enabled Solution: 1. Enable the 'CRPM option'. A. Enter the options and configurations setup using H3, ZD, Channel 11 and set the 'CRPM Option' to 'YES'.

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3402-Rail pressure sensor: Maximum rail pressure exceeded Control Module : ECU Context: This function is used for monitoring the rail pressure when the rail control loop is in limp home mode operated with a pressure relief valve (PRV). This fault has been generated due to the rail pressure exceeding the limiting value of 179 bar (2595.5 psi) over 2 s. Check the PRV is not sticking. Also, check the fuel backflow is not blocked and the low fuel pressure level is correct.

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3405-Turbocharger power stage - open circuit Control Module : ECU Context: ECU Power stages : Open load temperature error on the Turbocharger PWM output power stage. Cause: The ECU detects an open circuit in the turbocharger waste gate (WG) signal wire. Possible failure modes: 1. Faulty wiring 2. Faulty electric valve (WG) 3. Faulty ECU Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault codes: Start and operate machine. A. Fault code 3405 is not recorded again. OK to return the machine to service. B. Fault code 3405 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the electric Valve (WG) connector X-960. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the electric valve (WG) connector X-960. 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 actuator connector (1) Turn the key switch OFF. (2) Disconnect the electric valve (WG) connector X-960. (3) Turn the key switch ON. (4) Measure the voltage from electric valve (WG) connector X-960 +Battery pin 1 to chassis ground. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 10 V and 14.8 V. Go to Step 4. B. The voltage is less than 10 V. There is a problem in the battery supply to the valve. Check F-055. Repair as required. Return to Step 1 to confirm elimination of fault. 4. Measure the resistance through the valve (1) Turn the key switch OFF. (2) Disconnect the electric valve (WG) connector X-960. 47538922 29/05/2013

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(3) Measure the resistance through the valve (WG) windings between the component side of connector X-960 pins 1 and 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 valve windings. Temporarily replace the valve and retest. Return to Step 1 to confirm elimination of fault. 5. Measure the resistance through the signal wire (1) Turn the key switch OFF. (2) Disconnect the electric valve (WG) connector X-960. (3) Disconnect the ECU connector X-939. (4) Measure the resistance from the electric valve (WG) connector X-960 signal wire pin 2 to ECU connector X-939 pin 4, wire 391 (BK). The resistance should be less than 10 Ω. Wiggle the wire during measurement to reveal an intermittent condition. A. The resistance is less than 10 Ω. Temporarily replace the ECU 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 signal wire. Repair or replace the wire as required. Return to Step 1 to confirm elimination of fault.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3406-Turbocharger power stage - temperature too high Control Module : ECU Context: ECU Power stages : Over temperature error on the turbocharger PWM output power stage Cause: The ECU detects an excess current draw on the turbocharger waste gate (WG) signal wire. Possible failure modes: 1. Faulty wiring 2. Faulty electric valve (WG) 3. Faulty ECU Solution: 1. Verify that the fault code present on EST. (1) Access the Electronic Service Tool fault code screen and monitor the fault codes. (2) Verify that there are no fault codes pertaining to high battery voltage to the ECU or high fluid temperatures. A. Fault code 3406 is active with other fault codes such as FC3051 or FC3518 or FC3007. Troubleshoot these fault codes before troubleshooting FC3406. B. Fault code 3406 is not recorded again. OK to return the machine to service. C. Fault code 3406 is active and recorded again. Go to Step 2. 2. Measure the voltage at the actuator connector. (1) Turn the key switch OFF. (2) Disconnect the electric valve WG connector X-960. (3) Turn the key switch ON. (4) Measure the voltage from connector X-960 pin 1 to chassis ground. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 10 V and 14.8 V. Go to Step 3. B. The voltage is less than 10 V. There is a problem in the battery supply to the valve. Check F-055. Repair as required. Return to Step 1 to confirm elimination of fault. C. The voltage is greater than 14.9 V. There is a problem in the battery supply to the valve. Troubleshoot the high voltage problem. Refer to FC3051 Engine Control Unit (ECU) - Overvoltage (55.015). 3. Measure the resistance through the valve to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the electric valve WG connector X-960. (3) Measure the resistance through the component side of electric valve WG connector X-960 pin 1 to chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Go to Step 4. B. The resistance is less than 20,000 Ω. There is an internal short to chassis ground. Temporarily replace the Electric Valve and retest. Return to Step 1 to confirm elimination of the fault. 47538922 29/05/2013

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4. Measure the resistance through the signal wire. (1) Turn the key switch OFF. (2) Disconnect the electric valve WG connector X-960. (3) Disconnect the ECU connector X-939. (4) Measure the resistance from the ECU connector X-939 pin 4, wire 391 (BK) to chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the wire during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 10 Ω. There is a short circuit in the signal wire to chassis ground. Repair or replace the wire as required. Return to Step 1 to confirm elimination of fault.

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INT / WE markets Wire harnesses - Electrical NA market Wire harnesses - Electrical Wire harnesses - Electrical Wire harnesses - Electrical

schematic frame 01 (55.100.DP-C.20.E.01) schematic frame 01 (55.100.DP-C.20.E.01) schematic frame 18 (55.100.DP-C.20.E.18) schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3408-Lambda sensor - oxygen concentration too high Control Module : ECU Context: Cause: The expected O2 concentration is calculated using actual air flow and actual fuel injection. The calculated value is outside of the normal operating range. Possible failure modes: 1. Leakage or block in the exhaust gas system 2. Blocked fuel lines to the injector 3. Problem in the injection system 4. Problem in the wiring to the lambda (oxygen) sensor NOTE: When testing the lambda (oxygen) sensor a high impedance digital volt meter must be used. A normal analogue multi-meter will draw too much current and either burn out the sensor or give false readings. NOTE: When replacing the lambda (oxygen) sensor, re-flash the control module to allow for the new sensor adjustments to be learned. 5. Faulty lambda (oxygen) sensor 6. Faulty ECU Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Check the turbo exhaust system (1) Check the turbo and exhaust line for leaks and improper attachment. A. The exhaust system is free of leaks and improper attachment. Go to Step 3. B. The exhaust system has leaks and is need of repair. Repair the exhaust system as required. Return to Step 1 to confirm elimination of the fault. 3. Check the fuel injection system (1) Check the fuel lines to the injectors for leaks, blocks or improper attachment. A. The fuel lines are free of leaks, blocks and improper attachment. Go to Step 4. B. The fuel lines have leaks and are in need of repair. Repair the fuel lines as required. Return to Step 1 to confirm elimination of the fault. 4. Tiurn the key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. Return to Step 1 to confirm elimination of the fault. B. If no damage is found, reconnect connector X-943. Continue with step 5. 5. Measure the voltage at the sensor (1) Turn the key switch OFF

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(2) Disconnect the lambda (oxygen) sensor connector X-943. (3) Turn the key switch ON. (4) Measure the voltage between connector X-943 pin 4, wire 319 (GN/WH) and X-943 pin 2, wire 317 (GY). The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 11 V and 14.8 V. Go to Step 6. B. The voltage is less than 11 V. There is a problem in the battery supply to the sensor. Check fuse F-008. Repair as required. Return to Step 1 to confirm elimination of the fault. 6. Measure the resistance through the wire harness (1) Turn the key switch OFF. (2) Disconnect the ECU connector X-937 and the lambda (oxygen) sensor connector X-943 . (3) Measure the resistance between X-937 pin 7, wire 314 (GN) and X-943 pin 3, wire 314 (GN). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (4) Measure the resistance between X-937 pin 64, wire 316 (OR) and X-943 pin 1, wire 316 (OR). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (5) Measure the resistance between X-937 pin 86, wire 318 (YE) and X-943 pin 5, wire 318 (YE). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (6) Measure the resistance between X-937 pin 85, wire 317 (GY) and X-943 pin 2, wire 317 (GY). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (7) Measure the resistance between X-937 pin 63, wire 315 (BR) and X-943 pin 6, wire 315 (BR). 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 7. B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair as required. Go to Step 1 to confirm elimination of the fault. 7. Measure the resistance of the harness to chassis ground (1) Turn the key switch OFF. (2) Disconnect the ECU connector X-937 and the lambda (oxygen) sensor connector X-943. (3) Measure the resistance between X-937 pin 7, wire 314 (GN) and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (4) Measure the resistance between X-937 pin 64, wire 316 (OR) and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (5) Measure the resistance between X-937 pin 86, wire 318 (YE) and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (6) Measure the resistance between X-937 pin 85, wire 317 (GY) and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (7) Measure the resistance between X-937 pin 63, wire 315 (BR) and chassis ground. The resistance should be greater than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 Ω. Temporarily replace the lambda (oxygen) sensor 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 wiring harness. Repair as required. Go to Step 1 to confirm elimination of the fault.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3409-Engine oil pressure switch - oil pressure too low Control Module : ECU Context: The ECU has detected a low oil pressure Cause: Engine speed is greater than 500 RPM and the oil pressure switch did not close. The oil pressure switch will close to indicate to the ECU that the engine is running with the proper oil pressure. Possible failure modes: 1. Low engine oil level 2. Faulty engine lubrication system 3. Faulty electrical wiring, open circuit in the signal wire to the ECU 4. Faulty oil press switch 5. Faulty ECU Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. Fault code 3409 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the oil pressure switch connector X-959. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the oil pressure switch connector X-959. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. OK – The connectors are secure and the harness is free of damage. Go to Step 3. B. NOT OK – 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 through the signal wire (1) Turn the key switch OFF. (2) Disconnect ECU connector X-939 and the oil pressure switch connector X-959. (3) Measure the resistance between connector X-939 pin 6, wire 392 (BK/WH) and X-959 pin 1. 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 signal wire. repair as required. Go to Step 1 to confirm elimination of fault. 4. Measure the resistance through the oil pressure switch (1) Turn the key switch OFF. 47538922 29/05/2013

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(2) Disconnect the oil pressure switch connector X-959. (3) Start the engine. Set engine speed to 800 RPM. (4) While the engine is running, measure the resistance through the switch to chassis ground. The chassis ground connection should be clean and free of oil, paint and dirt. The resistance should be less than 10 Ω. A. The resistance is less than 10 Ω. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is greater than 10 Ω. There is a problem with the oil pressure switch. Temporarily replace the oil pressure switch and retest. Return to Step 1 to confirm elimination of fault.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3410-Throttle Valve Actuator (TVA) - positive position deviation limit exceeded Control Module : ECU Context: The positive limit of throttle valve governor deviation has been exceeded. Cause: Desired throttle valve position can not be reached due to sticking throttle valve. Possible throttle valve position sensor mismatched Possible failure modes: 1. Faulty wiring 2. Throttle valve binding inside assembly Solution: 1. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the TVA valve connector X966. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the TVA valve connector X966. Verify that the harness is free of damage, corrosion, abrasion or incorrect attachment. A. OK â&#x20AC;&#x201C; The connectors are secure and the harness is free of damage. Go to Step 2. B. NOT OK â&#x20AC;&#x201C; 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. 2. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, Ok to return the machine to service. B. If the fault is still present and active, temporarily replace the throttle valve assemble and retest. return to Step 1 to confirm elimination of the fault.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3411-Throttle Valve Actuator (TVA) - negative position deviation limit exceeded Control Module : ECU Context: The negative limit of throttle valve governor deviation has been exceeded. Cause: Desired throttle valve position can not be reached due to sticking throttle valve. Possible throttle valve position sensor mismatched Possible failure modes: 1. Faulty wiring 2. Throttle valve binding inside assembly Solution: 1. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the TVA valve connector X966. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the TVA valve connector X966. Verify that the harness is free of damage, corrosion, abrasion or incorrect attachment. A. OK â&#x20AC;&#x201C; The connectors are secure and the harness is free of damage. Go to Step 2. B. NOT OK â&#x20AC;&#x201C; 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. 2. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, Ok to return the machine to service. B. If the fault is still present and active, temporarily replace the throttle valve assemble and retest. return to Step 1 to confirm elimination of the fault.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3414-Glow plug of cylinder 1 - short circuit Control Module : ECU Context: The glow plug control unit (GCU) has detected a short circuit to ground in the glow plug control wire for cylinder number 1. Solution: 1. Verify that the fault code is still active (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. A fault code pertaining to the glow plugs is active. Fault code 3414 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-937, GCU connector X-938, the inline harness connector X-941 and glow plug 1 connector X-955 . All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the GCU connector X-938 to the glow plug 1 connector X-955. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. OK – The connectors are secure and the harness is free of damage. Go to Step 3. B. NOT OK – 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 through the glow plug wire. (1) Turn the key switch OFF. (2) Disconnect GCU connector X-938. Measure the resistance between the glow plug wire on connector X-938 pin 2, wire 384 (RD) to chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is approximately 1 Ω. Temporarily replace the GCU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 0.75 Ω. Go to Step 4. 4. Measure the resistance at the glow plug. (1) Turn the key switch OFF. (2) Disconnect the glow plug 1 connector X-955. (3) Measure the resistance between the component side of glow plug 1 connector X-955 pin 1 and chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. A. The resistance is approximately 1 Ω. There is a problem in the wiring to the glow plug. Repair or replace as required. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 0.75 Ω. Temporarily replace the glow plug and retest. Return to Step 1 to confirm elimination of the fault.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3415-Glow plug of cylinder 3 - short circuit Control Module : ECU Context: The glow plug control unit (GCU) has detected a short circuit to ground in the glow plug control wire for cylinder number 3. Solution: 1. Verify that the fault code is still active (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. A fault code pertaining to the glow plugs is active. Fault code 3415 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-937, GCU connector X-938, the inline harness connector X-941 and glow plug 3 connector X-957. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the GCU connector X-938 to the glow plug 3 connector X-957. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. OK – The connectors are secure and the harness is free of damage. Go to Step 3. B. NOT OK – 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 through the glow plug wire. (1) Turn the key switch OFF. (2) Disconnect GCU connector X-938. Measure the resistance between the glow plug wire on connector X-938 pin 1, wire 366 (RD/GN) to chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is approximately 1 Ω. Temporarily replace the GCU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 0.75 Ω. Go to Step 4. 4. Measure the resistance at the glow plug. (1) Turn the key switch OFF. (2) Disconnect the glow plug 3 connector X-957. (3) Measure the resistance between the component side of glow plug 3 connector X-957 pin 1 and chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. A. The resistance is approximately 1 Ω. There is a problem in the wiring to the glow plug. Repair or replace as required. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 0.75 Ω. Temporarily replace the glow plug and retest. Return to Step 1 to confirm elimination of the fault.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3416-Glow plug of cylinder 4 - short circuit Control Module : ECU Context: The glow plug control unit (GCU) has detected a short circuit to ground in the glow plug control wire for cylinder number 4. Solution: 1. Verify that the fault code is still active (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. A fault code pertaining to the glow plugs is active. Fault code 3416 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-937, GCU connector X-938, the inline harness connector X-941 and glow plug 4 connector X-958 . All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the GCU connector X-938 to the glow plug 4 connector X-958. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. OK – The connectors are secure and the harness is free of damage. Go to Step 3. B. NOT OK – 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 through the glow plug wire. (1) Turn the key switch OFF. (2) Disconnect GCU connector X-938. Measure the resistance between the glow plug wire on connector X-938 pin 6, wire 365 (RD/WH) to chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is approximately 1 Ω. Temporarily replace the GCU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 0.75 Ω. Go to Step 4. 4. Measure the resistance at the glow plug. (1) Turn the key switch OFF. (2) Disconnect the glow plug 4 connector X-958. (3) Measure the resistance between the component side of glow plug 4 connector X-958 pin 1 and chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. A. The resistance is approximately 1 Ω. There is a problem in the wiring to the glow plug. Repair or replace as required. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 0.75 Ω. Temporarily replace the glow plug and retest. Return to Step 1 to confirm elimination of the fault.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3417-Glow plug of cylinder 2 - short circuit Control Module : ECU Context: The glow plug control unit (GCU) has detected a short circuit to ground in the glow plug control wire for cylinder number 2. Solution: 1. Verify that the fault code is still active (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for Active fault codes: Start and operate machine. A. The fault is not recorded again. OK to return the machine to service. B. A fault code pertaining to the glow plugs is active. Fault code 3417 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-937, GCU connector X-938, the inline harness connector X-941 and glow plug 2 connector X-956. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the GCU connector X-938 to the glow plug 2 connector X-956. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. OK – The connectors are secure and the harness is free of damage. Go to Step 3. B. NOT OK – 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 through the glow plug wire. (1) Turn the key switch OFF. (2) Disconnect GCU connector X-938. Measure the resistance between the glow plug wire on connector X-938 pin 7, wire 377 (RD/BK) to chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is approximately 1 Ω. Temporarily replace the GCU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 0.75 Ω. Go to Step 4. 4. Measure the resistance at the glow plug. (1) Turn the key switch OFF. (2) Disconnect the glow plug 2 connector X-956. (3) Measure the resistance between the component side of glow plug 2 connector X-956 pin 1 and chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. A. The resistance is approximately 1 Ω. There is a problem in the wiring to the glow plug. Repair or replace as required. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 0.75 Ω. Temporarily replace the glow plug and retest. Return to Step 1 to confirm elimination of the fault.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3418-Turbocharger power stage - short circuit to battery Control Module : ECU Context: ECU Power stages: Short to battery error on the turbocharger PWM output power stage. Cause: The ECU detects a short to battery in the turbocharger waste gate (WG) signal wire. Possible failure modes: 1. Faulty wiring 2. Faulty electric valve waste gate (WG) 3. Faulty ECU Solution: 1. Verify that the fault code is active. (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for fault codes: Start and operate machine. A. Fault code 3418 is not recorded again. OK to return the machine to service. B. Fault code 3418 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the electric valve (WG) connector X-960 . All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the electric valve (WG) connector X-960. 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 actuator signal line (1) Turn the key switch OFF. (2) Disconnect the electric valve (WG) connector X-960 and the ECU connector X-939. (3) Turn the key switch ON. (4) Measure the voltage from ECU connector X-939 pin 4, wire 391 (BK) to chassis ground. The voltage should be less than 0.4 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.4 V. Go to Step 4. B. The voltage is greater than 0.5 V. There is a short circuit to another power source. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault. 4. Measure the resistance through the valve (1) Turn the key switch OFF. (2) Disconnect the electric valve (WG) connector X-960. 47538922 29/05/2013

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(3) Measure the resistance through the component side of connector X-960 pin 1 and pin 2. The resistance should be greater than 10 Ω. A. The resistance is greater than 10 Ω. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 10 Ω. There is an short circuit in the electric valve (WG) windings. Temporarily replace the valve and retest. Return to Step 1 to confirm elimination of fault.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3419-Turbocharger power stage - short circuit to ground Control Module : ECU Context: ECU Power stages: Short to ground error on the Turbocharger PWM output power stage. Cause: The ECU detects a short to ground in the turbocharger waste gate (WG) signal wire. Possible failure modes: 1. Faulty wiring 2. Faulty electric valve waste gate (WG) 3. Faulty ECU Solution: 1. Verify that the fault code is active. (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for fault codes: Start and operate machine. A. Fault code 3419 is not recorded again. OK to return the machine to service. B. Fault code 3419 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the electric valve (WG) connector X-960 . All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the electric valve (WG) connector X-960. 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 at the actuator signal line (1) Turn the key switch OFF. (2) Disconnect the electric valve (WG) connector X-960 and the ECU connector X-939. (3) Measure the resistance from ECU connector X-939 pin 4, wire 391 (BK) 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 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 valve (1) Turn the key switch OFF. (2) Disconnect the electric valve (WG) connector X-960.

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(3) Measure the resistance through the component side of connector X-960 pin 1 to chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is an short circuit in the electric valve (WG) windings. Temporarily replace the valve and retest. Return to Step 1 to confirm elimination of fault.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3425-Turbocharger - boost pressure deviation too high at intake air pressure and temperature sensor Control Module : ECU Context: The boost pressure exceeds the maximum limit for a period greater than 10.0 s. Cause: The engine control unit (ECU) is detecting inaccurate boost pressure. Possible failure modes: 1. Faulty wiring 2. Faulty boost pressure sensor 3. Fault EVGT actuator 4. Faulty ECU Solution: 1. Verify the fault code is present and active. A. If fault code is present and active, continue with step 2. B. If fault code is no longer present, return unit to proper operation. 2. Check for other faults present. Verify no other faults are associated to the Boost pressure sensor. A. If faults are present, correct those errors first. Then determine if this fault has been resolved. B. If no other faults are present, continue with step 3. 3. Check for other faults present. Verify no other faults that are associated to the EVGT actuator. A. If faults are present, correct those errors first. Then determine if this fault has been resolved. B. If no other faults are present, continue with step 4. 4. Check ECU for proper operation. If no other errors are present and all wiring is correct, download the latest version of the software. A. If fault code is no longer present, return unit to proper operation. B. If fault code is still active, replace the ECU. Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3426-Diesel Particulate Filter (DPF) - level 1 reached Control Module : ECU Context: The engine control unit (ECU) has detected an error associated with the diesel particulate filter (DPF). If this fault occurs, black smoke should be visible at the exhaust pipe. Check that the DPF is mounted properly and is not cracked. If the filter is not mounted properly, refit the filter correctly. If damage is determined, replace the filter.

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3428-Differential pressure sensor - signal not plausible Control Module : ECU Context: The 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 X-947 . 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 wholes. Repair or replace the air lines or sensor as required. Repair or replace the particulate filter as required.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3432-Exhaust Gas Recirculation (EGR) - inducement warning Control Module : ECU Context: The engine control unit (ECU) has detected a fault with the EGR valve and mild inducement level due to the EGR valve being blocked has been activated. Check for other error codes relating the to the EGR valve and continue to these tests.

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3435-Diesel Particulate Filter (DPF) - inducement warning Control Module : ECU Context: The engine control unit (ECU) has detected a fault with the diesel particulate filter (DPF) and mild inducement level due to â&#x20AC;&#x2DC;DPF inducementâ&#x20AC;&#x2122; has been activated. Check for other error codes relating the to the DPF and continue to these tests.

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Electrical systems - FAULT CODES

3517-Inlet air temperature sensor - signal too high Control Module : ECU Context: The engine control unit (ECU) generated an error from a fault associated with the ambient air temperature sensor. This error could result from a signal out of range or a signal that is erratic or intermittent. When the ECU determines that the Humidity/temperature sensor value is not valid, it will substitute a value of 29.96 Â°C (85.9 Â°F). Cause: The ambient air temperature sensor signal to the ECU is greater than 4.93 V. Possible failure modes: 1. Faulty electrical wiring or connections 2. Faulty ECU Solution: 1. Verify the fault code is still present and in an active state. 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, return machine to proper operation. 2. Check electrical connections and wiring. Check the connections and wiring from the ambient air temperature sensor connector X-942 to the ECU connector X-937 are secure and tight. Ensure all pins are clean and in good condition. A. If any connectors, wiring or pins are damaged, loose or corroded. Repair or replace as required. B. If all connections, wiring and pins are in good condition, continue with step 3. 3. Verify proper supply voltage to the sensor. Disconnect the ambient air temperature sensor connector X-942 and turn the ignition key switch ON. Measure the voltage between connector X-942 pin 1, wire 327 (OR) and ground. There should be approximately 4.9 V. A. If the voltage is 4.9 V or less, download the correct level of software. If the fault is still present, remove and replace the ECU. B. If there is greater than 5 V, continue to 4 4. Check for a short to above 5 V. A. Disconnect the ECU connector X-937. Turn the ignition key switch ON. Measure the voltage between connector X-942 pin 1, wire 327 (OR) and ground. X-942 pin 2, wire 328 (OR/BK) and ground. If a voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault is still present, remove and replace the engine controller.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3518-Inlet air temperature sensor - signal too low Control Module : ECU Context: The engine control unit (ECU) generated an error from a fault associated with the ambient air temperature sensor. This error could result from a signal out of range or a signal that is erratic or intermittent. When the ECU determines that the ambient air temperature sensor value is not valid, it will substitute a value of 29.96 Â°C (85.9 Â°F). Cause: The ambient air temperature sensor signal to the ECU is below 198 mV . Possible failure modes: 1. Faulty electrical wiring or connections 2. Faulty air temperature sensor 3. Faulty ECU Solution: 1. Verify this error code is still present and in an active state. A. If the error is still present and active, continue with step 2. B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Verify proper operation of the ambient air temperature sensor. Use electronic service tool (EST) to check the voltage range. The proper voltage range is 2.0 V to 4.9 V. A. If the voltage reading is low, less than 2.0 V. Continue with step 3. B. If the voltage reading is within the proper limits, fault may have been intermittent. Return machine to proper operation. 3. Disconnect the ambient air temperature sensor connector X-942 from the engine sensor harness. Use a multimeter to check between connector X-942 pin 1, wire 327 (OR) and ground. There should not be continuity to ground. A. If there is continuity. There is a short to ground in the sensor supply circuit. Continue with step 4. B. If there is not continuity. Leave ambient air temperature sensor X-942 disconnected and continue with step 5. 4. Disconnect connector X-937 at the ECU. Use multi-meter to check the harness side of connector X-937 pin 19, wire 327 (OR) to ground. There should not be continuity to ground. A. If there is continuity. There is a short between connector X-937 pin 19 and X-942 pin 1, wire 327 (OR). Locate and repair the damaged wires or replace the harness. B. If there is no continuity. The ECU has failed internally. Replace the ECU. 5. Disconnect connector X-937. Use a multi-meter to check for continuity between connector X-937 pin 20, wire 328 (OR/BK) to ground. A. If there is continuity, the short is in this wire.Locate and repair shorted wire. B. If there is no continuity, reconnect ambient air temperature sensor connector X-942 and continue with step 6. 6. Use a multi-meter to check for continuity between the harness side of connector X-937 pin 20, wire 328 (OR/BK) to ground. A. If there is continuity, the sensor has failed. Replace the sensor. B. If there is no continuity, the ECU has failed internally. Replace the ECU.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3648-Turbocharger - boost pressure deviation too high at intake air pressure and temperature sensor Control Module : ECU Context: If fault code is present refer to 3425-Turbocharger - boost pressure deviation too high at intake air pressure and temperature sensor (55.015) for troubleshooting.

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3650-Battery voltage - voltage too high Control Module : ECU NOTE: Check alternator output voltage. Troubleshoot charging system before proceeding. Context: The battery supply to the ECU is above the threshold. Verify the alternator output before continuing. Cause: 1. Faulty alternator 2. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the fault is still present, continue to step 2 2. Check for 12 V A. Turn the ignition key switch ON. Measure the voltage between connector X-937 pin 1, wire 31 (RD/BK) and ground X-937 pin 3, wire 30 (RD/YE) and ground X-937 pin 5, wire 29 (RD/YE) and ground X-937 pin 28, wire 28 (BK/WH) and ground If the voltage indicated is not approximately 12 Volts, repair or replace the alternator as required. B. If the ECU supply voltage is okay, download the correct level of software. If the fault is still present, remove and replace the ECU

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3651-Battery voltage - voltage too low Control Module : ECU NOTE: Check alternator output voltage. Troubleshoot charging system before proceeding. Possible failure modes: 1. Low battery voltage. 2. Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector. 3. Wiring or circuits shorted. 4. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the fault is still present, continue to step 2 2. Check for 12 V A. Turn the ignition key switch ON. Measure the voltage between connector X-937 pin 1, wire 31 (RD/BK) and ground X-937 pin 3, wire 30 (RD/YE) and ground X-937 pin 5, wire 29 (RD/YE) and ground X-937 pin 28, wire 28 (BK/WH) and ground If the voltage indicated is not approximately 12 Volts, repair or replace the alternator or battery as required. B. If the ECU supply voltage is okay, download the correct level of software. If the fault is still present, remove and replace the ECU

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3652-CAN-Bus - bus-off state of node A Control Module : ECU Possible failure modes: 1. Faulty connectors 2. Wiring fault 3. Engine control unit ( ECU) fault Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the tractor under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other error codes displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check the connector of the instrument cluster ( ADIC) X-450 and the connector of the engine control unit ECU X-937. A. Ensure that the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as necessary. B. If the connectors are okay, continue to step 4 4. Check all power supplies and grounds to the engine control unit ECU. A. If a fault is indicated, repair or replace the harness as required. B. If no faults are indicated, continue to step 5 5. Check for an open circuit on the CAN BUS. A. Disconnect the connector ADIC X-450 and the connector ECU X-937. Check between: X-937 ( CAN_H) pin 24, wire 0.75 (YE) and X-450 ( CAN_H) pin 3, wire 0.75 (YE) X-937 ( CAN_L) pin 25, wire 0.75 (GN) and X-450 ( CAN_L) pin 4, wire 0.75 (GN) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the engine control unit ECU.

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3657-CAN-Bus message timeout - CM1BC from ADIC Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: The ECU has detected a timeout of CM1BC CAN message. Possible failure modes: 1. Faulty harness 2. CAN BUS interference 3. Faulty ECU 4. Faulty central control unit ( CCU) Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the tractor under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other CAN related error codes displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check all power supplies and grounds to the controllers on the CAN BUS network. A. If a fault is indicated, repair or replace the harness as required. B. If the power supplies and grounds are okay, download the correct levels of controller software. If the fault is still present, remove and replace the ECU.

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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

14 15 17 18

(55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15) (55.100.DP-C.20.E.17) (55.100.DP-C.20.E.18)

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3663-Exhaust Gas Recirculation (EGR) - command saturation over higher limit Control Module : ECU Context: The positive limit of EGR valve governor deviation has been exceeded. Cause: Desired EGR valve position can not be reached due to sticking EGR valve. Possible EGR valve position sensor mismatched Possible failure modes: 1. Faulty wiring 2. EGR valve binding inside assembly Solution: 1. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 2. 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. 2. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, return the machine to service. B. If the fault is still present and active, temporarily replace the EGR valve assemble and retest. return to Step 1 to confirm elimination of the fault.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 547

Electrical systems - FAULT CODES

3664-Exhaust Gas Recirculation (EGR) - command saturation over lower limit Control Module : ECU Context: The negative limit of EGR valve governor deviation has been exceeded. Cause: Desired EGR valve position can not be reached due to sticking EGR valve. Possible EGR valve position sensor mismatched Possible failure modes: 1. Faulty wiring 2. EGR valve binding inside assembly Solution: 1. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 2. 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. 2. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, return the machine to service. B. If the fault is still present and active, temporarily replace the EGR valve assemble and retest. return to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 548

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 549

Electrical systems - FAULT CODES

3665-Exhaust Gas Recirculation (EGR) valve actuator - positive position deviation limit exceeded Control Module : ECU Context: The positive limit of EGR valve governor deviation has been exceeded. Cause: Desired EGR valve position can not be reached due to sticking EGR valve. Possible EGR valve position sensor mismatched Possible failure modes: 1. Faulty wiring 2. EGR valve binding inside assembly Solution: 1. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 2. 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. 2. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, return the machine to service. B. If the fault is still present and active, temporarily replace the EGR valve assemble and retest. return to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 550

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 551

Electrical systems - FAULT CODES

3666-Exhaust Gas Recirculation (EGR) valve actuator - negative position deviation limit exceeded Control Module : ECU Context: The negative limit of EGR valve governor deviation has been exceeded. Cause: Desired EGR valve position can not be reached due to sticking EGR valve. Possible EGR valve position sensor mismatched Possible failure modes: 1. Faulty wiring 2. EGR valve binding inside assembly Solution: 1. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 2. 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. 2. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, return the machine to service. B. If the fault is still present and active, temporarily replace the EGR valve assemble and retest. Return to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 552

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 553

Electrical systems - FAULT CODES

3667-Exhaust Gas Recirculation (EGR) valve actuator - open circuit at power stage Control Module : ECU Context: ECU Power stages : Open load error on the EGR valve power stage. Cause: The ECU detects an open circuit in the EGR valve drive circuit. Electrical problem in the EGR valve actuator. Possible failure modes: 1. Faulty wiring 2. Faulty EGR valve 3. Faulty ECU Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault codes: Start and operate machine. A. Fault code 3667 is not recorded again. OK to return the machine to service. B. Fault code 3667 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 through the wiring harness (1) Turn the key switch OFF. (2) Disconnect the EGR Valve connector X-964. Disconnect the ECU connector X-939. (3) Measure the resistance between ECU connector X-939 pin 50, wire 418 (GY) and EGR valve connector X-964 motor plus pin 1. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (4) Measure the resistance between ECU connector X-939 pin 35, wire 408 (TQ) and EGR valve connector X-964 motor minus pin 5. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (5) Measure the resistance between ECU connector X-939 pin 9, wire 394 (GN) and EGR valve connector X-964 position sensor supply pin 6. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

(6) Measure the resistance between ECU connector X-939 pin 39, wire 411 (RD) and EGR valve connector X-964 position sensor signal pin 2. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (7) Measure the resistance between ECU connector X-939 pin 24, wire 402 (BR/YE) and EGR valve connector X-964 position sensor ground pin 4. 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 wire as required. Return to Step 1 to confirm elimination of fault. 4. Measure the resistance through the valve (1) Turn the key switch OFF. (2) Disconnect the EGR valve connector X-964. (3) Measure the resistance through the motor windings on the component side of connector X-964 pin 1 and pin 5. The resistance should be less than 100 Ω. A. The resistance is less than 100 Ω. Temporarily replace the ECU 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 valve windings. Temporarily replace the valve and retest. Return to Step 1 to confirm elimination of fault.

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55.8 [55.DTC] / 555

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 556

Electrical systems - FAULT CODES

3668-Exhaust Gas Recirculation (EGR) valve actuator over-temperature at power stage Control Module : ECU Context: ECU Power stages : Over temperature error on the EGR valve output power stage Cause: The ECU detects an excess current draw on the EGR valve signal wire. Possible failure modes: 1. Faulty wiring 2. Faulty EGR valve 3. Faulty ECU Solution: 1. Verify that the fault code present on EST. (1) Access the Electronic Service Tool fault code screen and monitor the fault codes. (2) Verify that there are no fault codes pertaining to high battery voltage to the ECU or high fluid temperatures. A. Fault code 3668 is active with other fault codes such as FC3051 or FC3518 or FC3007. Troubleshoot these fault codes before troubleshooting FC3668. B. Fault code 3668 is not recorded again. OK to return the machine to service. C. Fault code 3668 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 through the wiring harness. (1) Turn the key switch OFF. (2) Disconnect the EGR valve connector X-964. Disconnect the ECU connector X-939. (3) Measure the resistance between ECU connector X-939 pin 50, wire 418 (GY) and EGR valve connector X-964 motor plus pin 1. 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 wire as required. Return to Step 1 to confirm elimination of fault. 4. Measure the resistance through the wiring harness to chassis ground. (1) Turn the key switch OFF. 47538922 29/05/2013

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Electrical systems - FAULT CODES

(2) Disconnect the EGR Valve connector X-964. Disconnect the ECU connector . (3) Measure the resistance between ECU connector X-939 pin 50, wire 418 (GY) and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (3) Measure the resistance between ECU connector X-939 pin 35, wire 408 (TQ) 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 wire as required. Return to Step 1 to confirm elimination of fault. 5. Measure the resistance through the valve to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the EGR valve connector X-964. (3). Measure the resistance through the component side of the EGR valve connector X-964 pin 1 to chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is an internal short to chassis ground. Temporarily replace the EGR valve and retest. Return to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 558

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 559

Electrical systems - FAULT CODES

3669-Exhaust Gas Recirculation (EGR) valve actuator - short circuit to battery on Out1 of power stage Control Module : ECU Context: Short circuit to battery on Out1 error for H-bridge. The ECU had detected a short circuit to an external power source. Cause: The EGR valve drive circuit is shorted to positive battery. Possible failure modes: 1. Wiring shorted to positive battery source. 2. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3669 is not recorded again. OK to return the machine to service. B. Fault code 3669 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 through the wiring harness (1) Turn the key switch OFF. (2) Disconnect the EGR valve connector X-964. Disconnect the ECU connector X-939. (3) Turn the key switch ON. (4) Measure the voltage from ECU connector X-939 pin 50, wire 418 (GY) to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. (5) Measure the voltage from ECU connector X-939 pin 35, wire 408 (TQ) 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. Temporarily replace the ECU 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. 47538922 29/05/2013

55.8 [55.DTC] / 560

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 561

Electrical systems - FAULT CODES

3670-Exhaust Gas Recirculation (EGR) valve actuator - short circuit to battery on Out2 of power stage Control Module : ECU Context: Short circuit to battery on Out2 error for H-bridge. The ECU had detected a short circuit to an external power source. Cause: The EGR valve drive circuit is shorted to positive battery. Possible failure modes: 1. Wiring shorted to positive battery source. 2. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3670 is not recorded again. OK to return the machine to service. B. Fault code 3670 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 through the wiring harness (1) Turn the key switch OFF. (2) Disconnect the EGR valve connector X-964. Disconnect the ECU connector X-939. (3) Turn the key switch ON. (4) Measure the voltage from ECU connector X-939 pin 50, wire 418 (GY) to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. (5) Measure the voltage from ECU connector X-939 pin 35, wire 408 (TQ) 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. Temporarily replace the ECU 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. 47538922 29/05/2013

55.8 [55.DTC] / 562

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 563

Electrical systems - FAULT CODES

3671-Exhaust Gas Recirculation (EGR) valve actuator - short circuit to ground on Out1 of power stage Control Module : ECU Context: The ECU had detected a short circuit to minus battery or chassis ground on Out1 error for H-bridge. Cause: The EGR valve drive circuit or wiring is shorted to minus battery or chassis ground. Possible failure modes: 1. Wiring shorted to minus battery or chassis ground. 2. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3671 is not recorded again. OK to return the machine to service. B. Fault code 3671 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 harness to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the EGR valve connector X-964. Disconnect the ECU connector X-939. (3) Measure the resistance from ECU connector X-939 pin 50, wire 418 (GY) to chassis ground. The resistance should be greater than 20,000 立 . Wiggle the harness during measurement to reveal an intermittent condition. (4) Measure the resistance from ECU connector X-939 pin 35, wire 408 (TQ) to chassis ground. The resistance should be greater than 20,000 立 . Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 立. Go to Step 4. B. The resistance is less than 20,000 立. There is a short circuit to chassis ground in the wiring harness. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 4. Measure the resistance of the valve to chassis ground.

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Electrical systems - FAULT CODES

(1) Turn the key switch OFF. (2) Disconnect the EGR valve connector X-964. (3) Measure the resistance from the component side of the EGR valve connector X-964 , motor plus pin 1 to chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU 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 EGR valve. Temporarily replace the valve and retest. Return to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 565

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 566

Electrical systems - FAULT CODES

3672-Exhaust Gas Recirculation (EGR) valve actuator - short circuit to ground on Out2 of power stage Control Module : ECU Context: The ECU had detected a short circuit to minus battery or chassis ground on Out2 error for H-bridge. Cause: The EGR valve drive circuit or wiring is shorted to minus battery or chassis ground. Possible failure modes: 1. Wiring shorted to minus battery or chassis ground. 2. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3672 is not recorded again. OK to return the machine to service. B. Fault code 3672 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 harness to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the EGR valve connector X-964. Disconnect the ECU connector X-939. (3) Measure the resistance from ECU connector X-939 pin 50, wire 418 (GY) to chassis ground. The resistance should be greater than 20,000 立 . Wiggle the harness during measurement to reveal an intermittent condition. (4) Measure the resistance from ECU connector X-939 pin 35, wire 408 (TQ) to chassis ground. The resistance should be greater than 20,000 立 . Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 立. Go to Step 4. B. The resistance is less than 20,000 立. There is a short circuit to chassis ground in the wiring harness. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 4. Measure the resistance of the valve to chassis ground.

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55.8 [55.DTC] / 567

Electrical systems - FAULT CODES

(1) Turn the key switch OFF. (2) Disconnect the EGR valve connector X-964. (3) Measure the resistance from the component side of the EGR valve connector X-964, motor plus pin 1 to chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU 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 EGR valve. Temporarily replace the valve and retest. Return to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 568

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 569

Electrical systems - FAULT CODES

3673-Exhaust Gas Recirculation (EGR) valve actuator - short circuit at power stage Control Module : ECU Context: The ECU had detected a short circuit in the ERG valve drive circuit. Cause: The ECU had detected a short circuit in the ERG valve drive circuit. Possible failure modes: 1. Wiring shorted. 2. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3673 is not recorded again. OK to return the machine to service. B. Fault code 3673 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 harness to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the EGR valve connector X-964. Disconnect the ECU connector X-939. (3) Measure the resistance between ECU connector X-939 pin 50, wire 418 (GY) and ECU connector X-939 pin 35, wire 408 (TQ). 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 in the wiring harness. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 4. Measure the resistance of the valve to chassis ground. (1) Turn the key switch OFF.

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Electrical systems - FAULT CODES

(2) Disconnect the EGR valve connector X-964. (3) Measure the resistance from the component side of the EGR valve connector X-964, motor plus pin 1 to chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU 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 EGR valve. Temporarily replace the valve and retest. Return to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 571

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 572

Electrical systems - FAULT CODES

3674-Exhaust Gas Recirculation (EGR) valve actuator under-voltage at power stage Control Module : ECU Context: Under voltage error for H-bridge. Cause: The ECU had detected a high fluctuations in the system voltage. Possible failure modes: 1. Bad battery or battery connection 2. Faulty alternator 3. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3674 is not recorded again. OK to return the machine to service. B. Fault code 3674 is recorded with other fault codes such as FC3051.Continue to test for battery or charging faults with the machine. C. Fault code 3674 is active and recorded again. Go to Step 2. 2. Inspect the battery cable connections. (1) Verify that the battery terminals and battery cables are free of corrosion, abrasion and incorrect attachment. (2) Verify that the battery chassis ground connection is clean and fastened securely to the frame. The chassis connection point should be free of paint, rust, dirt and debris. A. The cables and battery connections are secure and free of corrosion, abrasion and incorrect attachment. Go to Step 3. B. The battery connections or battery cables are in need of repair. Repair as required. Return to Step 1 to confirm elimination of the fault. 3. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connectors X-937 and X-939. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the Battery to the ECU connector X-937. 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. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. 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.

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55.8 [55.DTC] / 573

Electrical systems - FAULT CODES

3675-Long time EGR valve drift at closed position Control Module : ECU Context: The EGR valve actuator is monitored for long time drift by comparing first and last learned voltage compensation. The absolute value of the difference of the learned voltage values in the closed position and the first learned voltage value is above 200 mV. Cause: The EGR valve actuator is drifted or the fully closed position cannot be reached (blocked or sooted actuator). Possible failure modes: 1. The EGR valve actuator is drifted or the fully closed position cannot be reached (blocked or sooted actuator) Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, return the machine to service. B. If the fault is still present and active, temporarily replace the EGR valve assembly and retest. return to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 574

Electrical systems - FAULT CODES

3676-Exhaust Gas Recirculation (EGR) valve actuator - position sensor voltage too high Control Module : ECU Context: DFC for EGR valve position sensor voltage source high Cause: The ECU had detected a high voltage source in the EGR position sensor. Possible failure modes: 1. Faulty wiring 2. Faulty EGR valve 3. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3676 is not recorded again. OK to return the machine to service. B. Fault code 3676 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Turn the key switch OFF. (2) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (3) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 through the harness. (1) Turn the key switch OFF. (2) Disconnect the ECU connector X-939 and the EGR valve connector X-964. (3) Fabricate a jumper wire 20 cm (8 in). (4) Use the jumper wire to connect ECU connector X-939 pin 9, wire 394 (GN) to X-939 pin 39, wire 411 (RD). (5) Measure the resistance between EGR valve connector X-964 sensor supply pin 6 and EGR valve connector X-964 signal pin 2. The resistance should be less than 10 ÎŠ. Wiggle the harness during measurement to reveal an intermittent condition. (6) Use the jumper wire to connect ECU connector X-939 pin 24, wire 402 (BR/YE) to X-939 pin 39, wire 411 (RD). 47538922 29/05/2013

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(7) Measure the resistance between ERG valve connector X-964 sensor ground pin 4 and EGR valve connector X-964 sensor signal pin 2. 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 fault. 4. Measure for stray voltage to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the ECU connector X-939 . Disconnect the EGR valve connector X-964. (3) Turn the key switch ON. (4) Measure the voltage from ECU connector X-939 pin 9, wire 394 (GN) to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. (5) Measure the voltage from ECU connector X-939 pin 39, wire 411 (RD) to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. (6) Measure the voltage from ECU connector X-939 pin 24, wire 402 (BR/YE) 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 4. B. The voltage is greater than 0.5 V. There is a short circuit in the wiring to another voltage source. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault. 5. Measure the resistance through the position sensor (1) Turn the key switch OFF. (2) Disconnect the EGR valve connector X-964. (3) Measure the resistance between the component side of the EGR position sensor connector X-964 supply pin 6 and the signal pin 2. The resistance should be less than 10,000 Ω. If possible, move the valve while monitoring the resistance. The resistance should change at an even rate. (4) Measure the resistance between the component side of the EGR position sensor connector X-964 sensor supply ground pin 4 and sensor signal pin 2. The resistance should be less than 10,000 Ω. If possible, move the valve while monitoring the resistance. The resistance should change at an even rate. A. The resistance is less than 10,000 Ω and the resistance changes at an even rate when the valve is moved. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is greater than 10,000 Ω or the resistance did not change at a smooth rate. There is an open circuit in the valve position sensor. Temporarily replace the EGR valve and retest. Return to Step 1 to confirm elimination of fault.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3677-Exhaust Gas Recirculation (EGR) valve actuator - position sensor voltage too low Control Module : ECU Context: DFC for EGR valve position sensor voltage SRC low Cause: The ECU had detected a short circuit to ground in the EGR position sensor. Possible failure modes: 1. Faulty wiring 2. Faulty EGR valve 3. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3677 is not recorded again. OK to return the machine to service. B. Fault code 3677 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Turn the key switch OFF. (2) Inspect the ECU connector X-939 and the EGR valve connector X-964. All connections should be secure, tight, free of corrosion, abrasion and damage. (3) Inspect the harness from the ECU connector X-939 to the EGR valve connector X-964. 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 harness to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the ECU connector X-939 and the EGR valve connector X-964. (3) Measure the resistance from ECU connector X-939 pin 9, wire 394 (GN) to chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (3) Measure the resistance from ECU connector X-939 pin 39, wire 411 (RD) to chassis ground. The resistance should be greater than 20,000 Ω . Wiggle the harness during measurement to reveal an intermittent condition. (3) Measure the resistance from ECU connector X-939 pin 24, wire 402 (BR//YE) to 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

A. The resistance is greater than 20,000 Ω. Go to Step 4. B. The resistance is less than 20,000 Ω. There is an short circuit to chassis ground in the wiring. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault. 4. Measure resistance of the position sensor to chassis ground. (1) Turn the key switch OFF. (2) Measure the resistance from the component side of the EGR position sensor connector X-964 supply pin 6 to chassis ground. The resistance should be greater than 20,000 Ω. (3) Measure the resistance from the component side of the EGR position sensor connector X-964 signal pin 2 to chassis ground. The resistance should be greater than 20,000 Ω. (4) Measure the resistance from the component side of the EGR position sensor connector X-964 sensor ground pin 4 to chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU 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 position sensor. Temporarily replace the EGR valve and retest. Return to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 579

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3688-Water in fuel sensor - water in fuel detected or defective sensor Control Module : ECU Context: The Water in fuel detection is carried out with a digital sensor located in the fuel filter. Cause: The Engine Control Unit (ECU) has determined that there is either water in the fuel or a fault associated with the water in fuel sensor has occurred. Possible failure modes: 1. Water in fuel 2. Faulty connector 3. Faulty harness 4. Faulty water in fuel sensor Solution: 1. Drain the fuel filter of water and verify this error code is still present and in an active state. A. If the error is still present and active, continue to step 2 B. If the error is no longer present or is in an inactive state, return machine to proper operation. 2. Check the water in fuel sensor connector X-950, the ECU connector X-937 and the engine ground connector X-420 A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for 12 Volts. A. Disconnect connector X-950. Turn the key switch ON. Measure the voltage between connector X-950 pin 3, wire 345 (OR) and ground. If the voltage indicated is not approximately 12 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately 12 Volts, continue to step 4 4. Check for an open ground circuit. A. Turn the key switch OFF. Check between connector X-950 pin 2, wire 335 (BK) and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for an open circuit. A. Disconnect the controller connector X-937. Check between connector X-950 pin 1, wire 347 (YE) and X-937 pin 30, wire 347 (YE). If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 6 6. Check for a short to ground. A. Check between connector X-937 pin 1, wire 347 (YE) and ground. If a short to ground is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the water in fuel sensor.

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55.8 [55.DTC] / 581

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 582

Electrical systems - FAULT CODES

3689-Glow plug control module - faulty diagnostic data transmission or protocol fault Control Module : ECU Context: The engine control unit (ECU) has detected a faulty diagnostic data transmission or protocol error from the glow plug control unit (GCU). Cause: The ECU has detected a faulty diagnostic data transmission or protocol error from the glow plug control unit. Possible failure modes: 1. Battery voltage to the GCU 2. Wiring problem in the glow plug system 3. Faulty GCU 4. Faulty ECU Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault code: Start and operate machine. A. Fault code 3689 is not recorded again. OK to return the machine to service. B. Fault code 3689 is active. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-937, the GCU connector X-938, the inline engine harness connector X-941 and glow plug connectors X-955, X-956, X-957 and X-958. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the GCU connector X-938 to the glow plugs. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. OK â&#x20AC;&#x201C; The connectors are secure and the harness is free of damage. Go to Step 3. B. NOT OK â&#x20AC;&#x201C; 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 to the GCU. (1) Turn the key switch OFF. (2) Disconnect the GCU connector X-938. (3) Turn the key switch ON. (4) Measure the voltage from X-938 pin 4, wire 24 (OR/WH) to chassis ground. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 11 - 14.8 V. Go to Step 3.

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Electrical systems - FAULT CODES

B. The voltage is less than 11 V. There is a problem in the battery supply to the GCU. Check fuse F-004. Verify battery connections from the starter motor. Repair as required. Return to Step 1 to confirm elimination of the fault. 4. Measure the resistance of the glow plug ground wire and signal wires. (1) Turn the key switch OFF. (2) Disconnect the GCU connector X-938. Disconnect ECU connector X-937. (3) Measure the resistance between connector X-938 pin 5, wire 1020 (BK) and ECU connector X-937 pin 41, wire 333 (BL/RD). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (4) Measure the resistance between connector X-938 pin 8, wire 678 (GY) and ECU connector X-937 pin 52, wire 332 (GY). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (5) Measure the resistance between connector X-938 pin 3, wire 436 (BR/YE) and ECU connector X-937 pin 22, wire 334 (BR/YE). 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 GCU 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.

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55.8 [55.DTC] / 584

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18) Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3691-Glow plug control module - open circuit at power stage Control Module : ECU Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault code: Start and operate machine. A. A glow plug fault code is not recorded again. OK to return the machine to service. B. A fault code pertaining to the glow plugs is active. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-937, the glow plug control unit (GCU) connector X-938, the inline engine harness connector X-941 and glow plug connectors X-955, X-956, X-957 and X-958. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the GCU connector X-938 to the glow plugs. Verify that the harness is free of damage, corrosion, abrasion and incorrect attachment. A. OK – The connectors are secure and the harness is free of damage. Go to Step 3. B. NOT OK – 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 through the glow plug wire. (1) Turn the key switch OFF. (2) Disconnect GCU connector X-938. Measure the resistance between the glow plug wire on connector X-938 pins 2, 7, 1 and 6 to chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is approximately 1 Ω. Temporarily replace the GCU and retest. Go to Step 1 to confirm elimination of the fault. B. The resistance is greater than 1.5 Ω. Go to Step 4. 4. Measure the resistance at the glow plug. (1) Turn the key switch OFF. (2) Disconnect the glow plug connectors X-955, X-956, X-957 and X-958. (3) Measure the resistance between the component side of the glow plug connector X-955, X-956, X-957 and X-958 pin 1 and chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. A. The resistance is approximately 1 Ω. There is an open circuit in the wiring to the glow plug. Repair or replace as required. Go to Step 1 to confirm elimination of the fault. B. The resistance is greater than 1.5 Ω. Temporarily replace the glow plug and retest. Go to Step 1 to confirm elimination of the fault.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3692-Glow plug control module - over-temperature at power stage Control Module : ECU Context: The glow plug control unit (GCU) detects an over temperature error. Cause: Over temperature error on GCU power stage for glow plug low voltage system. Pre-glow and post-glow functions may be disabled while this code is active. There may be starting issues such as black smoke and hard starts while this code is active and the engine is cold. Possible failure modes: 1. High system voltage 2. High engine temperatures 3. Faulty wiring 4. Faulty GCU 5. Faulty ECU Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault code: Start and operate machine. A. Fault code 3692 is not recorded again. OK to return the machine to service. B. Fault code 3692 is recorded again. There are also fault codes for high battery voltage or high engine temperatures. Troubleshoot these codes before troubleshooting FC3692. C. Fault code 3692 is recorded and is active. Go to Step 2. 2. (1) Inspect the ECU connector X-937, the GCU connector X-938, the inline engine harness connector X-941 and glow plug connectors X-955, X-956, X-957 and X-958. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the GCU connector X-938 to the glow plugs. 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 to the GCU. (1) Turn the key switch OFF. (2) Disconnect the GCU connector X-938. (3) Turn the key switch ON. (4) Measure the voltage from X-938 pin 4, wire 24 (OR/WH) to chassis ground. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is between 11 - 14.8 V. Go to Step 4.

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Electrical systems - FAULT CODES

B. The voltage is less than 11 V. There is a problem in the battery supply to the GCU. Check fuse F-055. Verify battery connections from the starter motor. Repair as required. Return to Step 1 to confirm elimination of the fault. 4. Measure the resistance of the glow plug ground wire and signal wires. (1) Turn the key switch OFF. (2) Disconnect the GCU connector X-938. Disconnect ECU connector X-937. (3) Measure the resistance between connector X-938 pin 5, wire 1020 (BK) and ECU connector X-937 pin 41, wire 333 (BL/RD). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (4) Measure the resistance between connector X-938 pin 8, wire 678 (GY) and ECU connector X-937 pin 52, wire 332 (GY). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (5) Measure the resistance between connector X-938 pin 3, wire 436 (BR/YE) and ECU connector X-937 pin 22, wire 334 (BR/YE). 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 wiring. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 5. Measure the resistance through the glow plug wire. (1) Turn the key switch OFF. (2) Disconnect GCU connector X-938. Measure the resistance between the glow plug wire on connector X-938 pins 2, 7, 1 and 6 to chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is approximately 1 Ω. Temporarily replace the GCU and retest. Go to Step 1 to confirm elimination of the fault. B. The resistance is less than 0.5 Ω There is a short circuit in the wiring or glow plug. Go to Step 6. 6. Measure the resistance at the glow plug. (1) Turn the key switch OFF. (2) Disconnect the glow plug connectors X-955, X-956, X-957 and X-958. (3) Measure the resistance between the component side of the glow plug connector X-955, X-956, X-957 and X-958 pin 1 and chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. A. The resistance is approximately 1 Ω. There is a short circuit in the wiring to the glow plug. Repair or replace as required. Go to Step 1 to confirm elimination of the fault. B. The resistance is less than 0.5 Ω There is a short circuit in the glow plug. Temporarily replace the glow plug and retest. Go to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 589

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18) Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3693-Glow plug control module - short circuit to battery at power stage Control Module : ECU Context: The glow plug control GCU detects a short circuit to battery error. Cause: Short circuit to battery on GCU power stage for glow plug low voltage system. Pre-glow and post-glow functions may be disabled while this code is active. There may be starting issues such as black smoke and hard starts while this code is active and the engine is cold. Possible failure modes: 1. Faulty wiring 2. Faulty glow plug 3. Faulty GCU Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault code: Start and operate machine. A. A glow plug fault code is not recorded again. OK to return the machine to service. B. A fault code pertaining to the glow plugs is active. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-937, the GCU connector X-938, the inline engine harness connector X-941 and glow plug connectors X-955, X-956, X-957 and X-958. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the GCU connector X-938 to the glow plugs. 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 through the glow plug wire. (1) Turn the key switch OFF. (2) Disconnect GCU connector X-938. Measure the resistance between the glow plug wire on connector X-938 pins 2, 7, 1 and 6 to chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 ÎŠ. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is approximately 1 ÎŠ. Temporarily replace the GCU and retest. Go to Step 1 to confirm elimination of the fault. B. The resistance is greater than 1.5 ÎŠ. Go to Step 4. 4. Measure the resistance at the glow plug.

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Electrical systems - FAULT CODES

(1) Turn the key switch OFF. (2) Disconnect the glow plug connectors X-955, X-956, X-957 and X-958. (3) Measure the resistance between the component side of the glow plug connector X-955, X-956, X-957 and X-958 pin 1 and chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. A. The resistance is approximately 1 Ω. There is an open circuit in the wiring to the glow plug. Repair or replace as required. Go to Step 1 to confirm elimination of the fault. B. The resistance is greater than 1.5 Ω. Temporarily replace the glow plug and retest. Go to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 592

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 593

Electrical systems - FAULT CODES

3694-Glow plug control module - short circuit to ground at power stage Control Module : ECU Context: The glow plug control unit (GCU) detects a short circuit to ground error. Cause: Short circuit to ground error on (GCU) power stage for glow plug low voltage system. Pre-glow and post-glow functions may be disabled while this code is active. There may be starting issues such as black smoke and hard starts while this code is active and the engine is cold. Possible failure modes: 1. High system voltage 2. High engine temperatures 3. Faulty wiring 4. Faulty GCU 5. Faulty ECU Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault code: Start and operate machine. A. Fault code 3694 is not recorded again. OK to return the machine to service. B. Fault code 3694 is recorded again. There are also fault codes for high battery voltage or high engine temperatures. Troubleshoot these codes before troubleshooting FC3694. C. Fault code 3694 is recorded and is active. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-937, the GCU connector X-938, the inline engine harness connector X-941 and glow plug connectors X-955, X-956, X-957 and X-958. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the GCU connector X-938 to the glow plugs. 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 to the GCU. (1) Turn the key switch OFF. (2) Disconnect the GCU connector X-938. (3) Turn the key switch ON. (4) Measure the voltage from X-938 pin 4, wire 24 (OR/WH) to chassis ground. The voltage should be approximately 12 V. Wiggle the harness during measurement to reveal an intermittent condition. 47538922 29/05/2013

55.8 [55.DTC] / 594

Electrical systems - FAULT CODES

A. The voltage is between 11 - 14.8 V. Go to Step 4. B. The voltage is less than 11 V. There is a problem in the battery supply to the GCU. Check fuse F-004. Verify battery connections from the starter motor. Repair as required. Return to Step 1 to confirm elimination of the fault. 4. Measure the resistance of the glow plug ground wire and signal wires. (1) Turn the key switch OFF. (2) Disconnect the GCU connector X-938. Disconnect ECU connector X-937. (3) Measure the resistance between connector X-938 pin 5, wire 1020 (BK) and ECU connector X-937 pin 41, wire 333 (BL/RD). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (4) Measure the resistance between connector X-938 pin 8, wire 678 (GY) and ECU connector X-937 pin 52, wire 332 (GY). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (5) Measure the resistance between connector X-938 pin 3, wire 436 (BR/YE) and ECU connector X-937 pin 22, wire 334 (BR/YE). 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 wiring. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 5. Measure the resistance through the glow plug wire. (1) Turn the key switch OFF. (2) Disconnect GCU connector X-938. Measure the resistance between the glow plug wire on connector X-938 pins 2, 7, 1 and 6 to chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is approximately 1 Ω. Temporarily replace the GCU and retest. Go to Step 1 to confirm elimination of the fault. B. The resistance is less than 0.5 Ω There is a short circuit in the wiring or glow plug. Go to Step 6. 6. Measure the resistance at the glow plug. (1) Turn the key switch OFF. (2) Disconnect the glow plug connectors X-955, X-956, X-957 and X-958. (3) Measure the resistance between the component side of the glow plug connector X-955, X-956, X-957 and X-958 pin 1 and chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω. A. The resistance is approximately 1 Ω. There is a short circuit in the wiring to the glow plug. Repair or replace as required. Go to Step 1 to confirm elimination of the fault. B. The resistance is less than 0.5 Ω There is a short circuit in the glow plug. Temporarily replace the glow plug and retest. Go to Step 1 to confirm elimination of the fault.

47538922 29/05/2013

55.8 [55.DTC] / 595

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18) Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 596

Electrical systems - FAULT CODES

3707-Lambda sensor - open circuit at the nernst cell pin Control Module : ECU NOTE: When testing the lambda (oxygen) sensor a high impedance digital volt meter must be used. A normal analogue multi-meter will draw too much current and either burn out the sensor or give false readings. NOTE: Two people may be required to perform this test correctly. NOTE: When replacing the lambda (oxygen) sensor, re-flash the control module to allow for the new sensor adjustments to be learned. Context: The engine control unit has detected an intermittent signal on the Lambda (oxygen) sensor. This sensor is the primary measurement device for the fuel control to the ECU to know if the engine is too rich or too lean. Cause: The lambda (oxygen) sensor signal is not plausible. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty lambda (oxygen) sensor 3. Faulty control unit or software Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the ignition key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, reconnect the wiring harness to the sensor. Continue with step 3. 3. Test the lambda (oxygen) sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to warm up. Place the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-943 pin 3, wire 314 (GN) on the lambda (oxygen) sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V. A. If the voltage is not in range the sensor has failed. Replace the sensor. B. If the sensor is in range, continue with step 4. 4. Check for a grounded circuit. Place the ignition key switch in the OFF position. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943 and at ECU connector X-937 . Use a multi-meter to check for continuity from the engine harness side of connector X-937 pin 63, wire 315 (BR) to chassis ground. There should be no continuity. A. If there is continuity, the damaged wiring is in the engine harness between connector X-943 pin 6 and connector X-937 pin 63, wire 315 (BR). Locate and repair the damaged wiring harness. B. If there is no continuity, leave both connectors disconnected. Continue with step 5. 5. Check for a open circuit. Leave the ignition key switch in the OFF position. Use a multi-meter to check for continuity from the engine harness side of connector X-943 pin 6 and connector X-937 pin 63, 315 (BR). There should be continuity.

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55.8 [55.DTC] / 597

Electrical systems - FAULT CODES

A. If there is no continuity, the damaged wiring is in the engine harness between connector X-943 pin 6 and connector X-937 pin 63, 315 (BR) Locate and repair the damaged wiring harness. B. If there is continuity, re-flash ECU software. Check to verify the fault has cleared. If the fault has not cleared. Replace the ECU.

47538922 29/05/2013

55.8 [55.DTC] / 598

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 599

Electrical systems - FAULT CODES

3708-Lambda sensor - open circuit at the pump current pin Control Module : ECU NOTE: When testing the lambda (oxygen) sensor a high impedance digital volt meter must be used. A normal analogue multi-meter will draw too much current and either burn out the sensor or give false readings. NOTE: Two people may be required to perform this test correctly. NOTE: When replacing the lambda (oxygen) sensor, re-flash the control module to allow for the new sensor adjustments to be learned. Context: The engine control unit has detected an intermittent signal on the lambda (oxygen) current pump line. This sensor is the primary measurement device for the fuel control to the ECU to know if the engine is too rich or too lean. Cause: The lambda (oxygen) sensor signal is not plausible. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty lambda (oxygen) sensor 3. Faulty control unit or software Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the ignition key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, reconnect the wiring harness to the sensor. Continue with step 3. 3. Test the lambda (oxygen) sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to warm up. Place the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-943 pin 3, wire 314 (GN) on the lambda (oxygen) sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V. A. If the voltage is not in range the sensor has failed. Replace the sensor. B. If the sensor is in range, continue with step 4. 4. Check for a grounded circuit. Place the ignition key switch in the OFF position. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943 and at ECU connector X-937. Use a multi-meter to check for continuity from the engine harness side of connector X-937 pin 64, wire 316 (OR) to chassis ground. There should be no continuity. A. If there is continuity, the damaged wiring is in the engine harness between connector X-943 pin 1 and connector X-937 pin 64, wire 316 (OR). Locate and repair the damaged wiring harness. B. If there is no continuity, leave both connectors disconnected. Continue with step 5. 5. Check for a open circuit. Leave the ignition key switch in the OFF position. Use a multi-meter to check for continuity from the engine harness side of connector X-943 from pin 1 to connector X-937 pin 64, wire 316 (OR). There should be continuity.

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55.8 [55.DTC] / 600

Electrical systems - FAULT CODES

A. If there is no continuity, the damaged wiring is in the engine harness between connector X-943 from pin 1 to connector X-937 pin 64, wire 316 (OR). Locate and repair the damaged wiring harness. B. If there is continuity, re-flash ECU software. Check to verify the fault has cleared. If the fault has not cleared. Replace the ECU.

47538922 29/05/2013

55.8 [55.DTC] / 601

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

47538922 29/05/2013

55.8 [55.DTC] / 602

Electrical systems - FAULT CODES

3709-Lambda sensor - open circuit at the virtual ground pin Control Module : ECU NOTE: When testing the lambda (oxygen) sensor a high impedance digital volt meter must be used. A normal analogue multi-meter will draw too much current and either burn out the sensor or give false readings. NOTE: Two people may be required to perform this test correctly. NOTE: When replacing the lambda (oxygen) sensor, re-flash the control module to allow for the new sensor adjustments to be learned. Context: The engine control unit has detected an intermittent signal on the lambda (oxygen) sensors ground line. This sensor is the primary measurement device for the fuel control to the ECU to know if the engine is too rich or too lean. Cause: The lambda (oxygen) sensor signal is not plausible. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty lambda (oxygen) sensor 3. Faulty control unit or software Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the ignition key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, reconnect the wiring harness to the sensor. Continue with step 3. 3. Test the lambda (oxygen) sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to warm up. Place the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-943 pin 3, wire 314 (GN) on the lambda (oxygen) sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V. A. If the voltage is not in range the sensor has failed. Replace the sensor. B. If the sensor is in range, continue with step 4. 4. Check for a grounded circuit. Place the ignition key switch in the OFF position. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943 and at ECU connector X-937. Use a multi-meter to check for continuity from the engine harness side of connector X-937 pin 85, wire 317 (GY) to chassis ground. There should be no continuity. A. If there is continuity, the damaged wiring is in the engine harness between connector X-943 pin 2 and connector X-937 pin 85, wire 317 (GY). Locate and repair the damaged wiring harness. B. If there is no continuity, leave both connectors disconnected. Continue with step 5. 5. Check for a open circuit. Leave the ignition key switch in the OFF position. Use a multi-meter to check for continuity from the engine harness side of connector X-943 pin 2 and connector X-937 pin 85, wire 317 (GY). There should be continuity.

47538922 29/05/2013

55.8 [55.DTC] / 603

Electrical systems - FAULT CODES

A. If there is no continuity, the damaged wiring is in the engine harness between connector X-943 pin 2 and connector X-937 pin 85, wire 317 (GY). Locate and repair the damaged wiring harness. B. If there is continuity, re-flash ECU software. Check to verify the fault has cleared. If the fault has not cleared. Replace the ECU.

47538922 29/05/2013

55.8 [55.DTC] / 604

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 605

Electrical systems - FAULT CODES

3710-Lambda sensor - signal not plausible Control Module : ECU NOTE: When testing the lambda (oxygen) sensor a high impedance digital volt meter must be used. A normal analogue multi-meter will draw too much current and either burn out the sensor or give false readings. NOTE: When replacing the lambda (oxygen) sensor, re-flash the control module to allow for the new sensor adjustments to be learned. Context: The engine control unit (ECU) has detected the measured oxygen concentration is incorrect. This sensor is the primary measurement device for the fuel control to the ECU to know if the engine is too rich or too lean. Cause: The lambda (oxygen) sensor signal is not plausible. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty lambda (oxygen) sensor 3. Faulty EGR valve 4. Faulty control unit or software Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the ignition key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, reconnect the wiring harness to the sensor. Continue with step 3. 3. Test the lambda (oxygen) sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to warm up. Place the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-943 pin 3, wire 314 (GN) on the lambda (oxygen) sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V. A. If the voltage is not in range the sensor has failed. Replace the sensor. B. If the sensor is in range, continue with step 4. 4. Check the wiring harness for any short or open circuits. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943 and the ECU at connector X-937. Using a multi-meter to test the wiring harness, refer to the table below for test results. Test Type Continuity Continuity Continuity Continuity Continuity

From To X-943 pin 3, wire 314 (GN) X-937 pin 7, wire 314 (GN) X-943 pin 1, wire 316 (OR) X-937 pin 64, wire 316 (OR) X-943 pin 5, wire 318 (YE) X-937 pin 86, wire 318 (YE) X-943 pin 2, wire 317 (GY) X-937 pin 85, wire 317 (GN) X-943 pin 6, wire 315 (BR) X-937 pin 63, wire 315 (BR)

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55.8 [55.DTC] / 606

Result Continuity Continuity Continuity Continuity Continuity

Electrical systems - FAULT CODES

Test Type Short Circuit

From To Result X-943 pin 4, wire 319 (GN/ X-943 pin 3, wire 314 (GN) No continuity WH) X-943 pin 1, wire 316 (OR) X-943 pin 5, wire 318 (YE) X-943 pin 2, wire 317 (GY) X-943 pin 6, wire 315 (BR)

A. If any of the above tests fail. Locate and repair damaged wiring harness. B. If the all the above test are correct, continue with step 5. 5. Check the injection system for any leaks or damages. A. If the injectors or system has any leakages, repair or replace damage component. B. If the injection system is in good condition, continue with step 6. 6. Check the EGR valve. Remove the EGR valve, and check if the valve is stuck open. A. If the EGR valve is stuck open, clean or replace the EGR valve. B. If the EGR valve is in good condition, place the EGR valve back onto the machine. Re-flash the ECU software. Check to verify the fault has cleared. If the fault has not cleared. Replace the ECU.

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55.8 [55.DTC] / 607

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 608

Electrical systems - FAULT CODES

3711-Lambda sensor - short circuit to battery at heater power stage Control Module : ECU NOTE: When testing the lambda (oxygen) sensor a high impedance digital volt meter must be used. A normal analogue multi-meter will draw too much current and either burn out the sensor or give false readings. NOTE: Two people may be required to perform this test correctly. NOTE: When replacing the lambda (oxygen) sensor, re-flash the control module to allow for the new sensor adjustments to be learned. Context: The heater power stage of lambda (oxygen) sensor is monitored for a short circuit to battery, as long as the heater is working. Cause: The lambda (oxygen) sensor circuit is shorted to a high voltage source. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty lambda (oxygen) sensor 3. Faulty control unit or software Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the ignition key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, reconnect the wiring harness to the sensor. Continue with step 3. 3. Test the lambda (oxygen) sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to warm up. Place the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-943 pin 3, wire 314 (GN) on the lambda (oxygen) sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V. A. If the voltage is not in range the sensor has failed. Replace the sensor. B. If the sensor is in range, continue with step 4. 4. Check wiring for shorted to power source. Place the ignition key switch in the OFF position. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943 and at ECU connector X-937. Place the ignition key switch ON. Use a multi-meter to check for voltage from the engine harness side of connector X-943 pin 3, wire 314 (GN) to chassis ground. There should be no voltage. A. If there is voltage, the damaged wiring is in the engine harness between connector X-943 pin 3 and connector X-937 pin 7, wire 314 (GN). Locate and repair the damaged wiring harness. B. If there is no voltage, leave both connectors disconnected. Continue with step 5. 5. Check to see if the wiring is shorted to the relay circuit. Place the ignition key switch in the OFF position. Use a multi-meter to measure the resistance from the engine harness side of connector X-943 pin 3, wire 314 (GN) to pin 4, wire 319 (GN/WH). The resistance should be greater than 10.0 ÎŠ.

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55.8 [55.DTC] / 609

Electrical systems - FAULT CODES

A. If the resistance is below 10.0 Ω, the damaged wiring is in the engine harness between connector X-943 pin 3, wire 314 (GN) to pin 4, wire 319 (GN/WH). Locate and repair the damaged wiring harness. B. If the resistance is greater than 10.0 Ω, continue with step 6. 6. Check to see if the wiring is open. Place the ignition key switch in the OFF position. Use a multi-meter to measure the resistance from the engine harness side of connector X-943 pin 3, wire 314 (GN) to connector X-937 pin 7, wire 314 (GN). The resistance should be less than 10.0 Ω. A. If the resistance is greater than 10.0 Ω, the damaged wiring is in the engine harness between connector X-943 pin 3 and connector X-937 pin 7, wire 314 (GN). Locate and repair the damaged wiring harness. B. If the resistance is less than 10.0 Ω, continue with step 7. 7. Check software version is at the most current status. If the software version is not up to date, re-flash software and recheck fault is present. A. If the fault code is still active and present, replace the ECU. B. If the fault code has cleared, return machine to proper service.

47538922 29/05/2013

55.8 [55.DTC] / 610

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 611

Electrical systems - FAULT CODES

3712-Lambda sensor - short circuit to ground at heater power stage Control Module : ECU NOTE: When testing the lambda (oxygen) sensor a high impedance digital volt meter must be used. A normal analogue multi-meter will draw too much current and either burn out the sensor or give false readings. NOTE: Two people may be required to perform this test correctly. NOTE: When replacing the lambda (oxygen) sensor, re-flash the control module to allow for the new sensor adjustments to be learned. Context: The heater power stage of the lambda (oxygen) sensor is monitored against short circuit to ground, as long as the heater is working. Cause: The lambda (oxygen) sensor circuit is shorted to a ground source. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty lambda (oxygen) sensor 3. Faulty control unit or software Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the ignition key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, reconnect the wiring harness to the sensor. Continue with step 3. 3. Test the lambda (oxygen) sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to warm up. Place the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-943 pin 3, wire 314 (GN) on the lambda (oxygen) sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V. A. If the voltage is not in range the sensor has failed. Replace the sensor. B. If the sensor is in range, continue with step 4. 4. Check wiring for shorted to ground source. Place the ignition key switch in the OFF position. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943 and at ECU connector X-937. Place the ignition key switch ON. Use a multi-meter to measure the resistance from the engine harness side of connector X-943 pin 3, wire 314 (GN) to chassis ground. There should be approximately 1000 立. A. If there is less than 1000 立, the damaged wiring is in the engine harness between connector X-943 pin 3 and connector X-937 pin 7, wire 314 (GN). Locate and repair the damaged wiring harness. B. If there is approximately 1000 立, leave both connectors disconnected. Continue with step 5. 5. Check to see if the wiring is open. Place the ignition key switch in the OFF position. Use a multi-meter to measure the resistance from the engine harness side of connector X-943 pin 3 to connector X-937 pin 7, wire 314 (GN). The resistance should be less than 10.0 立.

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55.8 [55.DTC] / 612

Electrical systems - FAULT CODES

A. If the resistance is greater than 10.0 ÎŠ, the damaged wiring is in the engine harness between connector X-943 pin 3 and connector X-937 pin 7, wire 314 (GN). Locate and repair the damaged wiring harness. B. If the resistance is less than 10.0 ÎŠ, continue with step 6. 6. Check software version is at the most current status. If the software version is not up to date, re-flash software and recheck fault is present. A. If the fault code is still active and present, replace the ECU. B. If the fault code has cleared, return machine to proper service.

47538922 29/05/2013

55.8 [55.DTC] / 613

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 614

Electrical systems - FAULT CODES

3713-Lambda sensor: Open load error of the LSU heater power stage Control Module : ECU NOTE: When testing the lambda (oxygen) sensor a high impedance digital volt meter must be used. A normal analogue multi-meter will draw too much current and either burn out the sensor or give false readings. NOTE: Two people may be required to perform this test correctly. NOTE: When replacing the lambda (oxygen) sensor, re-flash the control module to allow for the new sensor adjustments to be learned. Context: The heater power stage of the lambda (oxygen) sensor is monitored against open load condition, as long as the heater is working. Cause: The lambda (oxygen) sensor circuit is has an open circuit condition. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty lambda (oxygen) sensor 3. Faulty control unit or software Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the ignition key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, reconnect the wiring harness to the sensor. Continue with step 3. 3. Test the lambda (oxygen) sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to warm up. Place the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-943 pin 3, wire 314 (GN) on the lambda (oxygen) sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V. A. If the voltage is not in range the sensor has failed. Replace the sensor. B. If the sensor is in range, continue with step 4. 4. Check for an open circuit. Place the ignition key switch in the OFF position. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943 and at ECU connector X-937. Use a multi-meter to check for continuity from the engine harness side of connector X-943 pin 3 to connector X-937 pin 7, wire 314 (GN). There should be continuity. A. If there is no continuity, the damaged wiring is in the engine harness between connector X-943 pin 3 and connector X-937 pin 7, wire 314 (GN). Locate and repair the damaged wiring harness. B. If there is continuity, re-flash ECU software. Check to verify the fault has cleared. If the fault has not cleared. Replace the ECU.

47538922 29/05/2013

55.8 [55.DTC] / 615

Electrical systems - FAULT CODES

47538922 29/05/2013

55.8 [55.DTC] / 616

Electrical systems - FAULT CODES

3713-Lambda sensor - open circuit at heater power stage Control Module : ECU NOTE: When testing the lambda (oxygen) sensor a high impedance digital volt meter must be used. A normal analogue multi-meter will draw too much current and either burn out the sensor or give false readings. NOTE: Two people may be required to perform this test correctly. NOTE: When replacing the lambda (oxygen) sensor, re-flash the control module to allow for the new sensor adjustments to be learned. Context: The heater power stage of the lambda (oxygen) sensor is monitored against open load condition, as long as the heater is working. Cause: The lambda (oxygen) sensor circuit is has an open circuit condition. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty lambda (oxygen) sensor 3. Faulty control unit or software Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the ignition key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, reconnect the wiring harness to the sensor. Continue with step 3. 3. Test the lambda (oxygen) sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to warm up. Place the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-943 pin 3, wire 314 (GN) on the lambda (oxygen) sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V. A. If the voltage is not in range the sensor has failed. Replace the sensor. B. If the sensor is in range, continue with step 4. 4. Check for an open circuit. Place the ignition key switch in the OFF position. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943 and at ECU connector X-937. Use a multi-meter to check for continuity from the engine harness side of connector X-943 pin 3 to connector X-937 pin 7, wire 314 (GN). There should be continuity. A. If there is no continuity, the damaged wiring is in the engine harness between connector X-943 pin 3 and connector X-937 pin 7, wire 314 (GN). Locate and repair the damaged wiring harness. B. If there is continuity, re-flash ECU software. Check to verify the fault has cleared. If the fault has not cleared. Replace the ECU.

47538922 29/05/2013

55.8 [55.DTC] / 617

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 618

Electrical systems - FAULT CODES

3714-Lambda sensor - oxygen ratio signal too high during calibration Control Module : ECU Context: The analogic lambda (oxygen) signal measured during calibration must be lower than 0.2 V. Cause: The analogic lambda (oxygen) signal is greater than 0.2 V during calibration. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty oxygen sensor 3. Problems with injection system or EGR 4. Faulty control unit or software Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Turn the key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943 and the ECU connector X-937. Inspect the ECU connector X-937 and lambda (oxygen) sensor connector X-943, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, reconnect connectors X-937 and X-943. Continue with step 3. 3. Test the lambda (oxygen) sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to warm up. Turn the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-943 pin 3, wire 314 (GN) on the lambda (oxygen) sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V. A. If the voltage is not in range the sensor has failed. Replace the sensor. B. If the sensor is in range, continue with step 4. 4. Check the wiring harness for any short or open circuits. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943 and the ECU at connector X-937. Using a multi-meter to test the wiring harness, refer to the table below for test results. Test Type Continuity Continuity Continuity Continuity Continuity Short Circuit

From X-943 X-943 X-943 X-943 X-943 X-943

pin pin pin pin pin pin

3 1 5 2 6 4

To X-937 X-937 X-937 X-937 X-937 X-943 X-943 X-943 X-943 X-943

pin pin pin pin pin pin pin pin pin pin

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7 64 86 85 63 3 1 5 2 6

Result Continuity Continuity Continuity Continuity Continuity No continuity

Electrical systems - FAULT CODES

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55.8 [55.DTC] / 620

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 621

Electrical systems - FAULT CODES

3715-Lambda sensor - oxygen ratio signal too low during calibration Control Module : ECU Context: The analogic lambda (oxygen) signal measured during calibration must be lower than 0.2 V. Cause: The analogic lambda (oxygen) signal is greater than 0.2 V during calibration. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty lambda (oxygen) sensor 3. Problems with injection system or EGR 4. Faulty control unit or software Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Turn the key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943 and the ECU connector X-937. Inspect the ECU connector X-937 and lambda (oxygen) sensor connector X-943, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, reconnect connectors X-937 and X-943. Continue with step 3. 3. Test the lambda (oxygen) sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to warm up. Turn the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-943 pin 3, wire 314 (GN) on the lambda (oxygen) sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V. A. If the voltage is not in range the sensor has failed. Replace the sensor. B. If the sensor is in range, continue with step 4. 4. Check the wiring harness for any short or open circuits. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943 and the ECU at connector X-937. Using a multi-meter to test the wiring harness, refer to the table below for test results. Test Type Continuity Continuity Continuity Continuity Continuity Short Circuit

From X-943 X-943 X-943 X-943 X-943 X-943

pin pin pin pin pin pin

3 1 5 2 6 4

To X-937 X-937 X-937 X-937 X-937 X-943 X-943 X-943 X-943 X-943

pin pin pin pin pin pin pin pin pin pin

7 64 86 85 63 3 1 5 2 6

A. If any of the above tests fail. Locate and repair damaged wiring harness.

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Result Continuity Continuity Continuity Continuity Continuity No continuity

Electrical systems - FAULT CODES

B. If the all the above test are correct, continue with step 5. 5. Check the injection system for any leaks or damages. A. If the injectors or system has any leakages, repair or replace damage component. B. If the injection system is in good condition, continue with step 6. 6. Check the EGR valve. Remove the EGR valve, and check if the valve is stuck open. A. If the EGR valve is stuck open, clean or replace the EGR valve. B. If the EGR valve is in good condition, place the EGR valve back onto the machine. Re-flash the ECU software. Check to verify the fault has cleared. If the fault has not cleared. Replace the ECU.

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55.8 [55.DTC] / 623

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 624

Electrical systems - FAULT CODES

3716-Lambda sensor - oxygen ratio signal too high Control Module : ECU Context: The analogic lambda (oxygen) signal measured during calibration must be between 200 mV and 4.7 V . Cause: The analogic lambda (oxygen) signal is greater than or equal to 4.7 V. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty lambda (oxygen) sensor 3. Faulty control unit or software Solution: 1. Verify that the fault code is active. (1) Use the Electronic Service Tool to clear all fault codes. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) To check for fault codes: Start and operate machine. A. Fault code 3716 is not recorded again. OK to return the machine to service. B. Fault code 3716 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-937 and the lambda (oxygen) sensor connector X-943. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-937 to the lambda (oxygen) sensor connector X-943 . 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 oxygen sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to warm up. Turn the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-943 pin 3, wire 314 (GN) on the lambda (oxygen) sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V. A. If the voltage is not in range the sensor has failed. Replace the sensor. B. If the sensor is in range, continue with step 4. 4. Check software version is at the most current status. If the software version is not up to date, re-flash software and recheck fault is present. A. If the fault code is still active and present, replace the ECU. B. If the fault code has cleared, return machine to proper service.

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55.8 [55.DTC] / 625

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 626

Electrical systems - FAULT CODES

3720-Lambda sensor - supply voltage too low Control Module : ECU Context: The SPI chip reports a "very low battery voltage" defect (i.e. Voltage is less than 9.0 V). Cause: A low voltage source has been detected. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty lambda (oxygen) sensor 3. Faulty ECU Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, leave the connector X-943 disconnected. Continue with step 3. 3. Check the wiring harness. Disconnect the engine harness from the ECU at connector X-937. Place the ignition switch OFF. Using a multi-meter to test the wiring harness, refer to the table below for test results. Test Type Resistance Resistance Resistance Resistance Resistance

From X-937 pin 64, wire 316 (OR) X-937 pin 85, wire 317 (GY) X-937 pin 7, wire 314 (GN) X-937 pin 86, wire 318 (YE) X-937 pin 63, wire 315 (BK)

To X-943 pin 1, wire 316 (OR) X-943 pin 2, wire 317 (GY) X-943 pin 3, wire 314 (GN) X-943 pin 5, wire 318 (YE) X-943 pin 6, wire 315 (BR)

Result Continuity Continuity Continuity Continuity Continuity

A. If any of the above tests fail. Locate and repair damaged wiring harness. B. If the all the above test are correct, replace the lambda (oxygen) sensor. Use EST to reset the ECU lambda (oxygen) sensor learning values. Recheck fault has cleared. If fault is still present, replace the ECU.

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55.8 [55.DTC] / 627

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 628

Electrical systems - FAULT CODES

3722-Lambda sensor - calculated temperature too high Control Module : ECU Context: The Lambda (oxygen) sensor measures O2 concentration only correctly, when the measuring cell is in a certain temperature range. The temperature is estimated by the inner resistance (Ri) of the heater. If the estimated temperature is higher than a threshold, a failure is reported. Cause: The calculated temperature (based on inner resistance) of the sensor exceeds 839.96 Â°C (1543.9 Â°F). Possible failure modes: 1. Disconnected lambda (oxygen) sensor 2. Faulty electrical wiring or connection 3. Faulty lambda (oxygen) sensor Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, leave the connector X-943disconnected. Continue with step 3. 3. Check the wiring harness. Disconnect the engine harness from the ECU at connector X-937. Place the ignition switch OFF. Using a multi-meter to test the wiring harness, refer to the table below for test results. Test Type Resistance Resistance Resistance Resistance Resistance

From X-937 pin 64, wire 316 (OR) X-937 pin 85, wire 317 (GY) X-937 pin 7, wire 314 (GN) X-937 pin 86, wire 318 (YE) X-937 pin 63, wire 315 (BR)

To X-943 pin 1, wire 316 (OR) X-943 pin 2, wire 317 (GY) X-943 pin 3, wire 314 (GN) X-943 pin 5, wire 318 (YE) X-943 pin 6, wire 315 (BR)

Result Continuity Continuity Continuity Continuity Continuity

A. If any of the above tests fail. Locate and repair damaged wiring harness. B. If the all the above test are correct, replace the lambda (oxygen) sensor. Use EST to reset the ECU oxygen sensor learning values.

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55.8 [55.DTC] / 629

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 630

Electrical systems - FAULT CODES

3723-Lambda sensor - calculated temperature too low Control Module : ECU Context: The lambda (oxygen) sensor measures O2 concentration only correctly, when the measuring cell is in a certain temperature range. The temperature is estimated by the inner resistance (Ri) of the heater. If the estimated temperature is higher than a threshold, a failure is reported. Cause: The calculated temperature (based on inner resistance) of the sensor is below or equal to 719.96 Â°C (1327.9 Â°F). Possible failure modes: 1. Disconnected lambda (oxygen) sensor 2. Faulty electrical wiring or connection 3. Faulty lambda (oxygen) sensor Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, leave the connector X-943 disconnected. Continue with step 3. 3. Check the wiring harness. Disconnect the engine harness from the ECU at connector X-937. Place the ignition switch OFF. Using a multi-meter to test the wiring harness, refer to the table below for test results. Test Type Resistance Resistance Resistance Resistance Resistance

From X-937 pin 64, wire 316 (OR) X-937 pin 85, wire 317 (GY) X-937 pin 7, wire 314 (GN) X-937 pin 86, wire 318 (YE) X-937 pin 63, wire 315 (BR)

To X-943 pin 1, wire 316 (OR) X-943 pin 2, wire 317 (GY) X-943 pin 3, wire 314 (GN) X-943 pin 5, wire 318 (YE) X-943 pin 6, wire 315 (BR)

Result Continuity Continuity Continuity Continuity Continuity

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55.8 [55.DTC] / 631

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 632

Electrical systems - FAULT CODES

3724-Lambda sensor - short circuit to battery Control Module : ECU Context: The SPI chip reports a "short circuit to battery" defect at any of the lines for Nernst Cell (UN), Virtual Ground (VG), or Pump Cell (IA,IP) Cause: There is a short to high source in the lambda (oxygen) sensor circuit. Possible failure modes: 1. Faulty electrical wiring or connection 2. Short to voltage on lines UN, VG, IA, IP 3. Open load in VG 4. Faulty lambda (oxygen) sensor Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, leave the connector X-943 disconnected. Continue with step 3. 3. Check the wiring harness. Disconnect the engine harness from the ECU at connector X-937. Place the ignition switch ON. Using a multi-meter to test the wiring harness, refer to the table below for test results. Test Type Voltage Voltage Voltage Voltage

From X-943 pin 1, wire 316 (OR) X-943 pin 2, wire 317 (GY) X-943 pin 5, wire 318 (YE) X-943 pin 6, wire 315 (BR)

To Ground Ground Ground Ground

Result No voltage No voltage No voltage No voltage

A. If any of the above tests fail. Locate and repair damaged wiring harness. B. If the all the above tests are correct, continue with step 4. 4. Check for an open circuit. Place the ignition switch OFF. Use a multi-meter to check for continuity on the engine harness from connector X-937 pin 85, wire 317 (GY) to connector X-943 pin 2, wire 317 (GY). There should be continuity. A. If there is no continuity, there is an open circuit in the engine harness between connector X-937 pin 85 to connector X-943 pin 2, wire 317 (GY). Locate and repair damaged wiring. B. If there is continuity, replace the lambda (oxygen) sensor. Use EST to reset the ECU lambda (oxygen) sensor learning values.

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55.8 [55.DTC] / 633

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 634

Electrical systems - FAULT CODES

3725-Lambda sensor - short circuit to ground Control Module : ECU Context: The SPI chip reports a "short circuit to ground" defect at any of the lines for Nernst Cell (UN), Virtual Ground (VG), or Pump Cell (IA,IP) Cause: There is a short to ground in the oxygen sensor circuit. Possible failure modes: 1. Faulty electrical wiring or connection 2. Short to ground on lines UN, VG, IA, IP 3. Faulty lambda (oxygen) sensor Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, leave the connector X-943 disconnected. Continue with step 3. 3. Check the wiring harness. Disconnect the engine harness from the ECU at connector X-937. Place the ignition switch OFF. Using a multi-meter to test the wiring harness, refer to the table below for test results. Test Type Resistance Resistance Resistance Resistance

From X-943 pin 1, wire 316 (OR) X-943 pin 2, wire 317 (GY) X-943 pin 5, wire 318 (YE) X-943 pin 6, wire 315 (BR)

To Ground Ground Ground Ground

Result No continuity No continuity No continuity No continuity

A. If any of the above tests fail. Locate and repair damaged wiring harness. B. If the all the above tests are correct, replace the lambda (oxygen) sensor. Use EST to reset the ECU lambda (oxygen) sensor learning values.

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55.8 [55.DTC] / 635

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 636

Electrical systems - FAULT CODES

3735-High pressure pump metering solenoid valve over-temperature Control Module : ECU Context: The engine control unit has determined that a short circuit condition exists in the fuel high pressure pump circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common rail. This error is the result of the power stage hardware report of 'excess temperature' (high current) in the metering unit circuit longer than 220 ms. Cause: Fuel high pressure pump circuit is shorted. Possible failure modes: 1. Faulty fuel high pressure pump, shorted solenoid coil (fuel metering unit). 2. Faulty control circuit, short circuit. 3. Faulty ECU, hardware or software. 4. Faulty ECU cooling system. Solution: 1. Disconnect the engine injector harness from the ECU at connector X-939. Use a multi-meter to check the resistance on the engine injector harness side of connector X-939 from pin 60, wire 424 (GY/WH) to pin 15, wire 400 (BR/GN). There should be approximately 3.2 Ω. A. If there is approximately 3.2 Ω, verify no other faults exist. If other faults are present, troubleshoot those faults first. If no other faults are present, check the ECU cooling system is operating correctly. B. If there is significantly less than 3.2 Ω, leave connector X-939 disconnected and continue with step 2. 2. Disconnect the engine injector harness from the fuel high pressure pump (fuel metering unit) at connector X-970. Use a multi-meter to check the resistance on connector X-970 of the fuel high pressure pump (fuel metering unit) solenoid coil between pins 1 and 2. There should be approximately 3.2 Ω. A. If there is approximately 3.2 Ω, leave connector X-970 disconnected and continue with step 3. B. If there is significantly less than 3.2 Ω, replace the fuel high pressure pump (fuel metering unit) solenoid coil. 3. Use a multi-meter to check for continuity from the engine injector harness side of connector X-970 pin 1 to the engine injector harness side of connector X-939 pin 15, wire 400 (BR/GN). There should be no continuity. A. If there is no continuity, leave the connectors X-939 and X-970 disconnected and continue with step 4. B. If there is continuity, the fuel high pressure pump (fuel metering unit) control circuit wires have been shorted together, locate and repair the shorted wires. 4. Use a multi-meter to check for continuity from the engine injector harness side of connector X-970 pin 2 to the engine injector harness side of connector X-970 pin 60, wire 424 (GY/WH). There should be no continuity. A. If there is no continuity, try reloading the ECU software and if the error reoccurs, replace the ECU. B. If there is continuity, the fuel high pressure pump control circuit wires have been shorted together, locate and repair the shorted wires.

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55.8 [55.DTC] / 637

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 638

Electrical systems - FAULT CODES

3736-Lambda sensor - oxygen ratio out of range Control Module : ECU Context: This electronic control unit (ECU) has detected a fault associated with the lambda (oxygen) sensor X-943. This fault is a result of a defective lambda (oxygen) sensor. Replace the lambda (oxygen) sensor X-943, and use EST to reset the learning values of the ECU.

47538922 29/05/2013

55.8 [55.DTC] / 639

Electrical systems - FAULT CODES

3737-Lambda sensor - over-temperature at heater power stage Control Module : ECU NOTE: When testing the lambda (oxygen) sensor a high impedance digital volt meter must be used. A normal analogue multi-meter will draw too much current and either burn out the sensor or give false readings. NOTE: When replacing the lambda (oxygen) sensor, re-flash the control module to allow for the new sensor adjustments to be learned. Context: The heater power stage of lambda (oxygen) sensor is monitored against over temperature (too high current). Cause: The SPI chip reports a "over temperature" defect. Possible failure modes: 1. Faulty electrical wiring or connection 2. Faulty lambda (oxygen) sensor 3. Faulty ECU or software. Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Turn the key switch OFF. Disconnect the engine harness from the lambda (oxygen) sensor at connector X-943. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, reconnect the lambda (oxygen) sensor connector X-943. Continue with step 3. 3. Test the lambda (oxygen) sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor to heat up. Turn the machine off. Use a back probe pin to connect the positive multi-meter lead to connector X-943 pin 3, wire 314 (GN) on the oxygen sensor. Place the negative lead to chassis ground. Have someone start the machine. Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V. A. If the voltage is not in range the sensor has failed. Replace the sensor. B. If the sensor is in range, continue with step 4. 4. Check software version is at the most current status. If the software version is not up to date, re-flash software and recheck fault is present. A. If the fault code is still active and present, replace the ECU. B. If the fault code has cleared, return machine to proper service.

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55.8 [55.DTC] / 640

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 641

Electrical systems - FAULT CODES

3762-Level 2 monitoring - sensor supply voltage too high Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. NOTE: Check alternator output voltage. Troubleshoot charging system before proceeding. Cause: The ECU also provides a 5 V supply for the sensors. This 5 V supply is monitored to ensure it remains within a certain range. The ECU. monitors the voltage against predetermined lower and upper thresholds. Possible failure modes: 1. Faulty wiring. 2. Faulty connectors 3. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the fault is still present, continue to step 2 2. Check for other engine sensor related error codes. A. If other engine sensor related error codes are displayed, continue to these tests. B. If no other engine sensor related error codes are displayed, continue to step 3 3. Check for 12 V A. Turn the ignition key switch ON. Measure the voltage between connector X-937 pin 1 (RD/BK) and ground X-937 pin 3 (RD/YE) and ground X-937 pin 5 (RD/YE) and ground X-937 pin 28 (BK/WH) and ground If the voltage indicated is not approximately 12 Volts, repair or replace the harness as required. B. If the ECU supply voltage is okay, download the correct level of software. If the fault is still present, remove and replace the ECU

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55.8 [55.DTC] / 642

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 643

Electrical systems - FAULT CODES

3763-Level 2 monitoring - sensor supply voltage too low Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. NOTE: Check alternator output voltage. Troubleshoot charging system before proceeding. Cause: The ECU also provides a 5 V supply for the sensors. This 5 V supply is monitored to ensure it remains within a certain range. The ECU. monitors the voltage against predetermined lower and upper thresholds. Possible failure modes: 1. Faulty wiring. 2. Faulty connectors 3. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the fault is still present, continue to step 2 2. Check for other engine sensor related error codes. A. If other engine sensor related error codes are displayed, continue to these tests. B. If no other engine sensor related error codes are displayed, continue to step 3 3. Check for 12 V A. Turn the ignition key switch ON. Measure the voltage between connector X-937 pin 1 (RD/BK) and ground X-937 pin 3 (D/YE) and ground X-937 pin 5 (RD/YE) and ground X-937 pin 28 (BK/WH) and ground If the voltage indicated is not approximately 12 Volts, repair or replace the harness as required. B. If the ECU supply voltage is okay, download the correct level of software. If the fault is still present, remove and replace the ECU

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55.8 [55.DTC] / 644

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

47538922 29/05/2013

55.8 [55.DTC] / 645

Electrical systems - FAULT CODES

3764-Main relay ECU - early opening fault Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: The Main relay is controlled by the engine control unit (ECU). After key off, the ECU goes into the ‘After-run’ where storage of the failures into the memory, counting of driving cycles and the corresponding reactions occur. The main relay is controlled by the ECU to assure the After-run. The main relay is switched off by the ECU itself after the After-run has finished. All these actions can not be done, if the main relay switches off before the After-run has finished. Therefore the correct opening of main relay is monitored. Cause: The ECU has detected the main relay has been switched off directly by key 15 and not by an ECU request. Possible failure modes: 1. Incorrect machine shut down sequence used 2. Faulty connector 3. Faulty ECU main relay 4. Faulty harness 5. Faulty ECU Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, make sure the machine is being shut down correctly using the ignition key switch. Check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check the ECU connector X-937 and the ECU main relay connector X-533 and the ECU main relay K–200 . A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check the ECU main relay K–200. A. Remove the ECU main relay K-200 and check the operation of the relay. If the relay does not operate correctly, replace the ECU main relay K–200. B. If the relay is okay, continue to step 4 4. Check for 12 V. A. Disconnect the ECU connector X-937 and remove the ECU main relay K–200. Turn the ignition key switch ON. Measure the voltage between connector X-937 pin 54, wire 341 (OR). If approximately 12 V is not indicated, repair or replace the harness as required. B. If approximately 12 V is indicated , continue to step 5 5. Check for 12 V. A. Turn the ignition key switch ON. Measure the voltage between the harness side of the ECU main relay: K–200 terminal 30 to ground K–200 terminal 86 to ground If approximately 12 V is not indicated, repair or replace the harness as required. 47538922 29/05/2013

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B. If approximately 12 V is indicated , continue to step 6 6. Check the ECU main relay fuses F-053 and F-054. A. If the fuse(s) are not okay, replace the blown fuse(s). If the fuse(s) blows again, there is a short to ground in the wiring harness, repair or replace as required. B. If the fuses are okay, continue to step 7 7. Check for an open circuit. A. Turn the ignition key switch OFF. Measure the voltage between the harness side of the ECU main relay: K–200 terminal 87 to connector X-937 pin 1 (RD/BK) K–200 terminal 87 to connector X-937 pin 3 (RD/YE) K–200 terminal 87 to connector X-937 pin 5 (RD/YE) K–200 terminal 85 to connector X-937 pin 28 (BK/WH) If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the fault is still present, remove and replace the ECU.

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3790-Diesel Particulate Filter (DPF) - flow resistance exceeded maximum limit Control Module : ECU Context: The flow resistance, dependent on soot mass stored in the particulate filter, should not exceed a defined limit. If this limit is exceeded, the diesel particulate filter is clogged, or a problem in the filter mounting should be assumed. Cause: The engine control unit (ECU) has detected the filtered flow is above maximum limit. Possible failure modes: 1. Diesel Particulate Filter (DPF) is clogged or not installed correctly. 2. Faulty wiring 3. Exhaust restriction 4. Faulty differential pressure sensor Solution: 1. Verify that the fault code is still active.. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for Active fault codes: Start and operate machine. A. Fault is not recorded again. OK to return the machine to service. B. Fault code 3790 is recorded again. Go to Step 2. 2. Turn the ignition key switch ON. Run the diesel particulate filter regeneration cycle. Turn the ignition key switch OFF for 1.0 min. Test drive the machine. Check if the fault code is still active or inactive. A. If the fault code is no longer active. OK to return machine to service. B. If the fault code is still active, continue with step 3. 3. Check the condition of the diesel particulate filter. Turn the ignition key switch OFF. Verify that the filter is installed correctly. A. If the filter is not installed correctly. Repair as required. B. If the filter is installed correctly, continue with step 4. 4. Check the differential pressure sensor is installed correctly. Turn the ignition key switch OFF. Visually inspect the differential pressure sensor at connector X-947 for physical damage, proper electrical connection and proper mechanical connection. Ensure all tubes and/or hoses connected to the sensor are in good working condition and properly connected at all ends. Visually inspect the entire exhaust system for bent, crushed or otherwise damaged tubes which may cause an exhaust system restriction. A. Damage is found, repair or replace as necessary. B. No damage is found, continue with step 5. 5. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-937 and the differential pressure sensor connector X-937. All connections should be secure, tight, free of corrosion, abrasion and damage.

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(2) Inspect the harness from the ECU connector X-937 to the differential pressure sensor connector X-947. 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 6. 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. 6. Measure the sensor voltage (1) Turn the key ignition switch OFF. (2) Disconnect the differential pressure sensor connector X-947 from the engine harness. Reconnect the ECU connector X-937. (3) Turn the key switch ON. (4) Measure the voltage between sensor connector X-947 pin 1, wire 329 (YE/BK) and X-947 pin 2, wire 330 (YE/BR). The voltage should be approximately 5 V. A. The voltage is approximately 5 V. Go to Step 7. B. The voltage is less than 5 V. There is a problem in the wiring to the sensor or the ECU sensor supply voltage. Repair as required. Return to Step 1 to confirm elimination of fault. 7. Measure the resistance through the wire (1) Disconnect the ECU connector X-937 and the differential pressure sensor connector X-947. (2) Measure the resistance from connector X-937 pin 58, wire 331 (YE) to X-947 pin 3, wire 331 (YE). The resistance should be less than 10 V. A. The resistance is less than 10 ÎŠ. Temporarily replace the differential pressure sensor and retest. Go to Step 1 to confirm elimination of the fault. B. The resistance is greater than 10 ÎŠ there is an open circuit in the signal wire. Repair as required. Return to Step 1 to confirm elimination of fault.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3794-Intake air pressure and temperature sensor - signal not plausible Control Module : ECU Context: The plausibility of boost pressure measured under low speed and load conditions is monitored. Boost pressure is compared with environmental pressure. The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The Boost Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to the pressure sensing function of the device. This error could result from a signal out of range or a signal that is either erratic or intermittent. Cause: The Boost Pressure sensor signal to the ECU is incorrect. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty boost pressure sensor Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue to step 2. 2. Check for other error codes. A. Check for other boost pressure related error codes. If other boost pressure sensor error codes are present, continue to those tests. B. If no other boost pressure related error codes are present, continue to step 3. 3. Check the boost pressure sensor connector X-961 and the ECU connector X-939. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 4 4. Check for 5 Volts. A. Disconnect connector X-961. Turn the key switch ON. Measure the voltage between connector X-961 pin 3 and ground. If the voltage indicated is not approximately 5 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately 5 Volts, continue to step 5 5. Check for an open ground circuit. A. Turn the key switch OFF. Check between connector X-961 pin 2 and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 6 6. Check for an open circuit. A. Disconnect connector X-939. Check between connector X-939 pin 40, wire 412 (RD/BK) and X-961 pin 4. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 7 47538922 29/05/2013

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7. Check for a short circuit. A. Check between connector: X-961 pin 4 and X-961 pin 3 X-961 pin 4 and X-961 pin 1 If a short circuit is indicated, repair or replace the harness as required. B. If the harness is okay, replace the boost pressure sensor.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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3795-Intake air pressure and temperature sensor - signal not plausible Control Module : ECU Context: The plausibility of boost pressure measured under low speed and load conditions is monitored. Boost pressure is compared with environmental pressure. The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The Boost Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to the pressure sensing function of the device. This error could result from a signal out of range or a signal that is either erratic or intermittent. Cause: The Boost Pressure sensor signal to the ECU is incorrect. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty boost pressure sensor Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue to step 2. 2. Check for other error codes. A. Check for other boost pressure related error codes. If other boost pressure sensor error codes are present, continue to those tests. B. If no other boost pressure related error codes are present, continue to step 3. 3. Check the boost pressure sensor connector X-961 and the ECU connector X-939. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 4 4. Check for 5 Volts. A. Disconnect connector X-961. Turn the key switch ON. Measure the voltage between connector X-961 pin 3 and ground. If the voltage indicated is not approximately 5 Volts, repair or replace the harness as required. B. If the voltage indicated is approximately 5 Volts, continue to step 5 5. Check for an open ground circuit. A. Turn the key switch OFF. Check between connector X-961 pin 2 and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 6 6. Check for an open circuit. A. Disconnect connector X-939. Check between connector X-939 pin 40, wire 412 (RD/BK) and X-961 pin 4. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 7 47538922 29/05/2013

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3797-Differential pressure sensor - signal too high Control Module : ECU Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Diesel Particulate Filter (DPF) pressure sensor. This fault is related to the pressure sensing function of the device. This error could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines that the DPF pressure sensor value is not valid, it will substitute a default value of 0.1 kPa (0.015 psi). Cause: The DPF pressure sensor signal to the ECU is out of range of the upper threshold limit. Possible failure modes: 1. Faulty pressure sensor. 2. Faulty electrical wiring or connection. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Check electrical connections and wiring. Place the ignition key switch OFF. Remove DPF pressure sensor connector X-947 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the DPF pressure sensor. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace DPF pressure sensor if damaged. B. If no damage is determined, proceed to step 2. 2. Check Open Circuit Voltages for DPF pressure sensor. Place the ignition key switch OFF. Remove X-947 connector from DPF pressure sensor, place the ignition key switch ON and check for voltages (DC) between connector pins outlined in the table below. Test Type 1. Voltage 3. Voltage

From X-947 pin 1 X-947 pin 3

To X-947 pin 2 X-947 pin 2

Expected Results Approx. 5 volts Approx. 5 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3. 3. Check for Faulty Wiring. Place the ignition key switch OFF. Remove and perform continuity/shorts tests between connectors X-947 and connector X-937 on engine wiring harness. Flex harness during test to check for any intermittent operation. Use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multi-meter (DMM) to connector X-937. Make sure the DMM's test lead resistance is taken into account when making continuity measurements. See test table below. Important Note: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type 1. Continuity

From: X-947 pin 1

2. Continuity

X-947 pin 2

To: Expected Results X-937 pin 14, wire 329 (YE/ Approx. 0 - 0.10 ohms BK) X-937 pin 36, wire 330 (YE/ Approx. 0 - 0.10 ohms BR)

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3. Continuity 5. Shorts

6. Shorts

X-947 pin 3 X-937 pin 58, wire 331 (YE) Approx. 0 - 0.10 ohms X-937 pin 58, wire 331 (YE) X-937 pin 14, wire 329 (YE/ Open Circuit BK), pin 36, wire 330 (YE/ BR) X-937 pin 36, wire 330 (YE/ X-937 pin 14, wire 329 (YE/ Open Circuit BR) BK)

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Check for ECU Voltages and Ground Continuity. Use product schematic. Place the ignition key switch OFF. Remove connector X-937 from the ECU. Place the ignition key switch ON to check for voltage at the appropriate pins defined in the test table below. Place the ignition key switch OFF to check for continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to connector X-937. Make sure the DMM's test lead resistance is taken into account when making any continuity measurements. Important Note: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type 1. Voltage

2. Continuity

From To X-937 pin 1 (RD/BK), pin Ground (engine block) 3 (RD/YE), pin 5 (RD/YE), pin 54 (OR) X-937 pin 2 (BK), pin 4 Ground (engine block) (BK), pin 6 (BK)

Expected Results Approx. 12 volts

Approx. 0 - 0.10 ohms

A. If the voltages and ground paths are correct and the DPF pressure sensor was not replaced on a prior diagnostic of this type, replace the pressure sensor. B. If the voltages and ground paths are correct and the DPF pressure sensor was replaced on a prior diagnostic of this type, re-initialize the ECU as if it was blank (new) and load the appropriate data-set. C. If the voltages and ground paths are correct and the ECU was re-initialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to schematic and determine root cause of power or continuity problem(s).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3798-Differential pressure sensor - signal too low Control Module : ECU Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Diesel Particulate Filter (DPF) pressure sensor. This fault is related to the pressure sensing function of the device. If the sensed value of the DPF pressure sensor signal is below 0.22 V. Cause: The DPF pressure sensor circuit l to the ECU is shorted to ground or open. Possible failure modes: 1. Faulty sensor. 2. Faulty electrical wiring or connection. 3. Faulty ECU Solution: 1. Verify the fault is present. Check electrical connections and wiring. Place the ignition key switch OFF. Remove DPF pressure sensor connector X-947 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the DPF pressure sensor. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace DPF pressure sensor if damaged. B. If no damage is determined, leave connector X-947. Continue with step 2. 2. Check wiring harness for short to ground. Place the ignition key switch OFF. Disconnect the DPF pressure sensor connector X-947. Place the ignition key switch ON. Using a multi-meter check for voltage from the engine harness side of connector X-947 pin 1 to pin 3 There should be approximately 5.0 V. A. If there is no voltage, continue with step 3. B. If there is voltage continue with step 6. 3. Check for a grounded circuit. Place the ignition key switch OFF. Disconnect the engine harness from the ECU at connector X-937. Use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the multi-meter to check for continuity from the engine harness side of connector X-937 pin 14, wire 329 (YE/BK) to chassis ground. There should be no continuity. A. If there is continuity, the short to ground condition is in the engine harness between connector X-947 pin 1 and connector X-937 pin 14, wire 329 (YE/BK). Locate and repair damaged wiring. B. If there is no continuity, leave the connectors disconnected. Continue with step 4. 4. Check for a short circuit. Place the ignition key switch OFF. Use a multi-meter to check for continuity on the engine harness of connector X-947 pin 1, wire 329 (YE/BK) to pin 2, wire 330 (YE/BR). There should be no continuity. A. If there is continuity the wiring harness is shorted together. Locate and repair damaged wiring. B. If there is no continuity, continue with step 5. 5. Locate the open circuit. Place the ignition key switch OFF. Use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the multi-meter to check for continuity from the engine harness side of connector X-947 pin 1, wire 329 (YE/BK) to connector X-937 pin 14, wire 329 (YE/BK). There should be continuity. A. If there is no continuity, there is an open circuit in the engine harness between connector X-947 pin 1, wire 329 (YE/BK) and connector X-937 pin 14, wire 329 (YE/BK).. Locate and repair damaged wiring. B. If there is continuity, leave connector X-937 disconnected. Continue with step 10.

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6. Check the DPF pressure sensor. Clear all fault codes that may be stored. Check to see if any faults are present. Fault code 3798 should be present. A. If the fault code 3798 is present, the sensor has failed. Replace the sensor. B. If the fault code is not present continue with step 7. 7. Check for short to ground condition. Place the ignition key switch OFF. Disconnect the engine control harness from the ECU at connector X-937. Use a multi-meter to check for continuity from the engine harness side of connector X-947 pin 2, wire 330 (YE/BR) to chassis ground. There should be no continuity. A. If there is continuity, the short to ground condition is in the engine harness between connector X-937 pin 2 and connector X-947 pin 2, wire 330 (YE/BR). Locate and repair damaged wiring. B. If there is no continuity, continue with step 8. 8. Check for a short circuit. Place the ignition key switch OFF. Use a multi-meter to check for continuity on the engine harness of connector X-947 pin 2, wire 330 (YE/BR) to pin 3, wire 331 (YE). There should be no continuity. A. If there is continuity the wiring harness is shorted together. Locate and repair damaged wiring. B. If there is no continuity, continue with step 9. 9. Check for an open circuit. Place the ignition key switch OFF. Use a multi-meter to check for continuity from the engine harness connector X-947 pin 3, wire 331 (YE) to connector X-937 pin 58, wire 331 (YE). There should be continuity. A. If there is no continuity, there is an open circuit in the engine harness between connector X-947 pin 3, wire 331 (YE) and connector X-937 pin 58, wire 331 (YE). Locate and repair damaged wiring. B. If there is continuity, continue with step 10. 1 Locate the open circuit. Place the ignition key switch ON. Use a multi-meter to check for voltage on the ECU 0. connector X-937 pin 14, to chassis ground. There should be approximately 5.0 V. Then check for continuity from the ECU connector X-937 pin 36 ,to chassis ground. There should be continuity. A. If the readings are incorrect, use wiring schematics to check that the supply voltages and grounds are present. B. If the readings are correct, try reloading the software. Recheck that the fault has cleared. If the fault has not cleared, check all connections are clean, and secure. Check for any damaged wiring, and repair as necessary.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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Electrical systems - FAULT CODES

3801-Exhaust manifold pressure sensor - signal too high Control Module : ECU Context: The engine control unit (ECU) has detected the turbine upstream pressure sensor sensed voltage is above 4.74 V. Cause: The turbine upstream pressure sensor signal is shorted to a high voltage source. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty turbine upstream pressure sensor Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check the turbine upstream pressure sensor connector X-963 and the ECU connector X-939. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for 5 V. A. Disconnect connector X-963. Turn the ignition key switch ON. Measure the voltage between connector X-963 pin 1 and ground. If approximately 5 V is not indicated, repair or replace the harness as required. B. If approximately 5 V is indicated, continue to step 4 4. Check for an open ground circuit. A. Check between connector X-963 pin 2 and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for a short to a positive voltage. A. Disconnect connector X-939. Turn the ignition key switch ON. Measure the voltage between connector X-963 pin 3 and ground. If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 6 6. Check for a short to ground. A. Turn the ignition key switch OFF. Check between connector X-963 pin 3 and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 7 7. Check for an open circuit. A. Check between connector X-939 pin 43, wire 414 (RD/BL) and X-963 pin 3. If an open circuit is indicated, repair or replace the harness as required.

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B. If the harness is okay, remove and replace the turbine upstream pressure sensor.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3802-Exhaust manifold pressure sensor - signal too low Control Module : ECU Context: The engine control unit (ECU) has detected the turbine upstream pressure sensor sensed voltage is below 427.80 mV. Cause: The turbine upstream pressure sensor signal is shorted to a ground source. Possible failure modes: 1. Faulty connector 2. Faulty harness 3. Faulty turbine upstream pressure sensor Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check the turbine upstream pressure sensor connector X-963 and the ECU connector X-939. A. Ensure the connectors are connected, not damaged, the pins are in the correct position and that the fit is tight. Repair or replace as required. B. If the connectors are okay, continue to step 3 3. Check for 5 V. A. Disconnect connector X-963. Turn the ignition key switch ON. Measure the voltage between connector X-963 pin 1 and ground. If approximately 5 V is not indicated, repair or replace the harness as required. B. If approximately 5 V is indicated, continue to step 4 4. Check for an open ground circuit. A. Check between connector X-963 pin 2 and ground. If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicated, continue to step 5 5. Check for a short to a positive voltage. A. Disconnect connector X-939. Turn the ignition key switch ON. Measure the voltage between connector X-963 pin 3 and ground. If a voltage is indicated, repair or replace the harness as required. B. If a voltage is not indicated, continue to step 6 6. Check for a short to ground. A. Turn the ignition key switch OFF. Check between connector X-963 pin 3 and ground. If a short to ground is indicated, repair or replace the harness as required. B. If a short to ground is not indicated, continue to step 7 7. Check for an open circuit. A. Check between connector X-939 pin 43, wire 414 (RD/BL) and X-963 pin 3. If an open circuit is indicated, repair or replace the harness as required. 47538922 29/05/2013

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B. If the harness is okay, remove and replace the turbine upstream pressure sensor.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Electrical systems - FAULT CODES

3810-Common rail pressure sensor - intermittent signal Control Module : ECU Context: The engine control unit (ECU) has detected an intermittent fault in rail pressure signal. Cause: There is a loose connection in the rail pressure circuit. Possible failure modes: 1. Faulty wiring or connection 2. Faulty sensor Solution: 1. Disconnect the engine sensor harness from the rail pressure sensor connector X-967. Inspect connector housing body/latch, pins, and wiring harness for damage. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good sound electrical connection. B. If no damaged is determine, continue with step 2. 2. Check the rail pressure sensor. Inspect connector X-967 housing body/latch, pins. A. If damage is determined after careful inspection, replace the sensor. Re-flash the ECU. B. If no damaged is found. Clear fault and return machine to proper operation.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 671

Electrical systems - FAULT CODES

3818-Throttle Valve Actuator (TVA) - open circuit Control Module : ECU Context: ECU Power stages : Open load error on the throttle valve actuator (TVA) valve power stage. Cause: The ECU detects an open circuit in the TVA valve drive circuit. Electrical problem in the TVA valve actuator. Possible failure modes: 1. Faulty wiring 2. Faulty TVA valve 3. Faulty ECU Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for fault codes: Start and operate machine. A. Fault code 3818 is not recorded again. OK to return the machine to service. B. Fault code 3818 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939, the inline harness connector X-941 and the TVA valve connector X966 . All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the TVA valve connector X966. 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 through the wiring harness (1) Turn the key switch OFF. (2) Disconnect the TVA Valve connector X966. Disconnect the ECU connector X-939. (3) Measure the resistance between ECU connector X-939 pin 49, wire 416 (RD/YE) and TVA valve motor plus connector X966 pin 6. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (4) Measure the resistance between ECU connector X-939 pin 34, wire 407 (OR/WH) and TVA valve motor minus connector X966 pin 2. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (5) Measure the resistance between ECU connector X-939 pin 8, wire 393 (BK/YE) and TVA position sensor supply connector X966 pin 1. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

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Electrical systems - FAULT CODES

(6) Measure the resistance between ECU connector X-939 pin 53, wire 419 (GY/BK) and TVA position sensor signal connector X966 pin 5. The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (7) Measure the resistance between ECU connector X-939 pin 37, wire 409 (TQ/GN) and TVA position sensor ground connector X966 pin 3. 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 wire as required. Return to Step 1 to confirm elimination of fault. 4. Measure the resistance through the valve (1) Turn the key switch OFF. (2) Disconnect the TVA valve connector X966. (3) Measure the resistance through the motor windings between the component side of connector X966 pin 2 and pin 6. The resistance should be less than 100 Ω. A. The resistance is less than 100 Ω. Temporarily replace the ECU 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 valve windings. Temporarily replace the valve and retest. Return to Step 1 to confirm elimination of fault.

47538922 29/05/2013

55.8 [55.DTC] / 673

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 674

Electrical systems - FAULT CODES

3819-Throttle Valve Actuator (TVA) - over-current at power stage Control Module : ECU Context: ECU Power stages : Over temperature error on the throttle valve actuator (TVA) PWM output power stage Cause: The ECU detects an excess current draw on the TVA signal wire. Possible failure modes: 1. Faulty wiring 2. Faulty TVA valve 3. Faulty ECU Solution: 1. Verify that the fault code present on EST. (1) Access the Electronic Service Tool fault code screen and monitor the fault codes. (2) Verify that there are no fault codes pertaining to high battery voltage to the ECU or high fluid temperatures. A. Fault code 38189 is active with other fault codes such as FC3051 or FC3518 or FC3007. Troubleshoot these fault codes before troubleshooting FC3820. B. Fault code 3819 is not recorded again. OK to return the machine to service. C. Fault code 3819 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the TVA valve connector X966. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the TVA valve connector X966. 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 through the wiring harness. (1) Turn the key switch OFF. (2) Disconnect the TVA Valve connector X966. Disconnect the ECU connector X-939. (3) Measure the resistance between ECU connector X-939 pin 49, wire 416 (RD/YE) and TVA valve motor plus connector X966 pin 6. 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 wire as required. Return to Step 1 to confirm elimination of fault. 4. Measure the resistance through the wiring harness to chassis ground. (1) Turn the key switch OFF.

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Electrical systems - FAULT CODES

(2) Disconnect the TVA Valve connector X966. Disconnect the ECU connector X-939. (3) Measure the resistance between ECU connector X-939 pin 49, wire 416 (RD/YE) and chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition. (3) Measure the resistance between ECU connector X-939 pin 34, wire 407 (OR/WH) 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 wire as required. Return to Step 1 to confirm elimination of fault. 5. Measure the resistance through the TVA Valve to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the TVA Valve connector X966. (3) Measure the resistance from the component side the TVA Valve connector X966 pin 1 to chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 Ω. There is an internal short to chassis ground. Temporarily replace the TVA Valve and retest. Return to Step 1 to confirm elimination of the fault.

47538922 29/05/2013

55.8 [55.DTC] / 676

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 677

Electrical systems - FAULT CODES

3820-Throttle Valve Actuator (TVA) - over-temperature at power stage Control Module : ECU Context: ECU Power stages : Over temperature error on the throttle valve actuator (TVA) PWM output power stage Cause: The ECU detects an excess current draw on the TVA signal wire. Possible failure modes: 1. Faulty wiring 2. Faulty TVA valve 3. Faulty ECU Solution: 1. Verify that the fault code present on EST. (1) Access the Electronic Service Tool fault code screen and monitor the fault codes. (2) Verify that there are no fault codes pertaining to high battery voltage to the ECU or high fluid temperatures. A. Fault code 3820 is active with other fault codes such as FC3051 or FC3518 or FC3007. Troubleshoot these fault codes before troubleshooting FC3820. B. Fault code 3820 is not recorded again. OK to return the machine to service. C. Fault code 3820 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the TVA valve connector X966. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the TVA valve connector X966. 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 through the wiring harness. (1) Turn the key switch OFF. (2) Disconnect the TVA Valve connector X966. Disconnect the ECU connector X-939. (3) Measure the resistance between ECU connector X-939 pin 49, wire 416 (RD/YE) and TVA valve motor plus connector X966 pin 6. 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 wire as required. Return to Step 1 to confirm elimination of fault. 4. Measure the resistance through the wiring harness to chassis ground. (1) Turn the key switch OFF. 47538922 29/05/2013

55.8 [55.DTC] / 678

Electrical systems - FAULT CODES

47538922 29/05/2013

55.8 [55.DTC] / 679

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 680

Electrical systems - FAULT CODES

3821-Throttle Valve Actuator (TVA) - short circuit to battery at Out1 of power stage Control Module : ECU Context: Short circuit to battery on Out1 error for H-bridge. The ECU had detected a short circuit to an external power source. Cause: The throttle valve actuator (TVA) valve drive circuit is shorted to positive battery. Possible failure modes: 1. Wiring shorted to positive battery source. 2. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3821 is not recorded again. OK to return the machine to service. B. Fault code 3821 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the TVA valve connector X966. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the TVA valve connector X966. 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 through the wiring harness (1) Turn the key switch OFF. (2) Disconnect the TVA valve connector X966. Disconnect the ECU connector X-939. (3) Turn the key switch ON. (4) Measure the voltage from ECU connector X-939 pin 49, wire 416 (RD/YE) to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. (5) Measure the voltage from ECU connector X-939 pin 34, wire 407 (OR/WH) 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. Temporarily replace the ECU 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. 47538922 29/05/2013

55.8 [55.DTC] / 681

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 682

Electrical systems - FAULT CODES

3822-Throttle Valve Actuator (TVA) - short circuit to battery at Out2 of power stage Control Module : ECU Context: Short circuit to battery on Out2 error for H-bridge. The ECU had detected a short circuit to an external power source. Cause: The throttle valve actuator (TVA) valve drive circuit is shorted to positive battery. Possible failure modes: 1. Wiring shorted to positive battery source. 2. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3822 is not recorded again. OK to return the machine to service. B. Fault code 3822 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the TVA valve connector X966. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the TVA valve connector X966. 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 through the wiring harness (1) Turn the key switch OFF. (2) Disconnect the TVA valve connector X966. Disconnect the ECU connector X966. (3) Turn the key switch ON. (4) Measure the voltage from ECU connector X-939 pin 49, wire 416 (RD/YE) to chassis ground. The voltage should be less than 0.5 V. Wiggle the harness during measurement to reveal an intermittent condition. (5) Measure the voltage from ECU connector X-939 pin 34, wire 407 (OR/WH) 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. Temporarily replace the ECU 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. 47538922 29/05/2013

55.8 [55.DTC] / 683

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 684

Electrical systems - FAULT CODES

3823-Throttle Valve Actuator (TVA) - short circuit to ground at Out1 of power stage Control Module : ECU Context: The ECU had detected a short circuit to minus battery or chassis ground on Out1 error for H-bridge. Cause: The throttle valve actuator (TVA) valve drive circuit or wiring is shorted to minus battery or chassis ground. Possible failure modes: 1. Wiring shorted to minus battery or chassis ground. 2. Faulty TVA valve 3. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3823 is not recorded again. OK to return the machine to service. B. Fault code 3823 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the TVA valve connector X966. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the TVA valve connector X966. 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 harness to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the TVA valve connector X966. Disconnect the ECU connector X-939. (3) Measure the resistance from ECU connector X-939 pin 49, wire 416 (RD/YE) to chassis ground. The resistance should be greater than 20,000 立 . Wiggle the harness during measurement to reveal an intermittent condition. (4) Measure the resistance from ECU connector X-939 pin 34, wire 407 (OR/WH) to chassis ground. The resistance should be greater than 20,000 立 . Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 立. Go to Step 4. B. The resistance is less than 20,000 立. There is a short circuit to chassis ground in the wiring harness. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 47538922 29/05/2013

55.8 [55.DTC] / 685

Electrical systems - FAULT CODES

4. Measure the resistance of the valve to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the TVA valve connector X966. (3) Measure the resistance from the component side of the TVA valve, motor plus connector X966 pin 6 to chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU 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 solenoid valve. Temporarily replace the valve and retest. Return to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 686

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 687

Electrical systems - FAULT CODES

3824-Throttle Valve Actuator (TVA) - short circuit to ground at Out2 of power stage Control Module : ECU Context: The ECU had detected a short circuit to minus battery or chassis ground on Out2 error for H-bridge. Cause: The throttle valve actuator (TVA) valve drive circuit or wiring is shorted to minus battery or chassis ground. Possible failure modes: 1. Wiring shorted to minus battery or chassis ground. 2. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3824 is not recorded again. OK to return the machine to service. B. Fault code 3824 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the TVA valve connector X966. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the TVA valve connector X966. 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 harness to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the TVA valve connector X966. Disconnect the ECU connector X-939. (3) Measure the resistance from ECU connector X-939 pin 49, wire 416 (RD/YE) to chassis ground. The resistance should be greater than 20,000 立 . Wiggle the harness during measurement to reveal an intermittent condition. (4) Measure the resistance from ECU connector X-939 pin 34, wire 407 (OR/WH) to chassis ground. The resistance should be greater than 20,000 立 . Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 立. Go to Step 4. B. The resistance is less than 20,000 立. There is a short circuit to chassis ground in the wiring harness. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 4. Measure the resistance of the valve to chassis ground. 47538922 29/05/2013

55.8 [55.DTC] / 688

Electrical systems - FAULT CODES

(1) Turn the key switch OFF. (2) Disconnect the TVA valve connector X966.. (3) Measure the resistance from the component side of the TVA valve, motor plus connector X966 pin 6 to chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU 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 TVA valve. Temporarily replace the valve and retest. Return to Step 1 to confirm elimination of the fault.

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55.8 [55.DTC] / 689

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 690

Electrical systems - FAULT CODES

3825-Throttle Valve Actuator (TVA) - short circuit at power stage Control Module : ECU Context: The ECU had detected a short circuit in the throttle valve actuator (TVA) valve drive circuit. Cause: The ECU had detected a short circuit in the TVA valve drive circuit. Possible failure modes: 1. Wiring shorted. 2. Faulty TVA valve 3. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3825 is not recorded again. OK to return the machine to service. B. Fault code 3825 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the TVA valve connector X966. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the TVA valve connector X966. 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 harness to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the TVA valve connector X966. Disconnect the ECU connector X-939. (3) Measure the resistance between ECU connector X-939 pin 49, wire 416 (RD/YE) and ECU connector X-939 pin 34, wire 407 (OR/WH). 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 in the wiring harness. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 4. Measure the resistance of the valve to chassis ground. (1) Turn the key switch OFF.

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Electrical systems - FAULT CODES

(2) Disconnect the TVA valve connector X966. (3) Measure the resistance from the TVA valve, motor plus connector X966 pin 6 to chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU 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 solenoid valve. Temporarily replace the valve and retest. Return to Step 1 to confirm elimination of the fault.

47538922 29/05/2013

55.8 [55.DTC] / 692

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 693

Electrical systems - FAULT CODES

3826-Throttle Valve Actuator (TVA) - temperature dependent over-current at power stage Control Module : ECU Context: The ECU had detected a short circuit in the throttle valve actuator (TVA) valve drive circuit. Cause: The ECU had detected a short circuit in the TVA valve drive circuit. Possible failure modes: 1. Wiring shorted. 2. Faulty TVA valve 3. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3826 is not recorded again. OK to return the machine to service. B. Fault code 3826 is active and recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-939 and the TVA valve connector X966. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-939 to the TVA valve connector X966. 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 harness to chassis ground. (1) Turn the key switch OFF. (2) Disconnect the TVA valve connector X966. Disconnect the ECU connector X-939. (3) Measure the resistance between ECU connector X-939 pin 49, wire 416 (RD/YE) and ECU connector X-939 pin 34, wire 407 (OR/WH). 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 in the wiring harness. Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault. 4. Measure the resistance of the valve to chassis ground. (1) Turn the key switch OFF. 47538922 29/05/2013

55.8 [55.DTC] / 694

Electrical systems - FAULT CODES

47538922 29/05/2013

55.8 [55.DTC] / 695

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 696

Electrical systems - FAULT CODES

3827-Throttle Valve Actuator (TVA) - under-voltage at power stage Control Module : ECU Context: Under voltage error for H-bridge. Cause: The ECU had detected a high fluctuations in the system voltage. Possible failure modes: 1. Bad battery or battery connection 2. Faulty alternator 3. Faulty ECU Solution: 1. Check for active fault codes. (1) Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (2) Use the Electronic Service Tool to clear all fault codes. (3) To check for fault codes: Start and operate machine. A. Fault code 3827 is not recorded again. OK to return the machine to service. B. Fault code 3827 is recorded with other fault codes such as FC3051. Continue to test for battery or charging faults with the machine. C. Fault code 3827 is active and recorded again. Go to Step 2. 2. Inspect the battery cable connections. (1) Verify that the battery terminals and battery cables are free of corrosion, abrasion and incorrect attachment. (2) Verify that the battery chassis ground connection is clean and fastened securely to the frame. The chassis connection point should be free of paint, rust, dirt and debris. A. The cables and battery connections are secure and free of corrosion, abrasion and incorrect attachment. Go to Step 3. B. The battery connections or battery cables are in need of repair. Repair as required. Return to Step 1 to confirm elimination of the fault. 3. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connectors X-937 and X-939. All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the Battery to the ECU connector X-937. 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. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. 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.

47538922 29/05/2013

55.8 [55.DTC] / 697

Electrical systems - FAULT CODES

3830-Throttle Valve Actuator (TVA) - position signal too high Control Module : ECU Context: The engine control unit (ECU) monitors the electrical signal of the diesel fluid contaminant (DFC) for throttle valve actuator (TVA) position sensor. Cause: The calculated TVA position is above the maximum physical range. Possible failure modes: 1. Faulty wiring 2. Faulty TVA sensor Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the ignition key switch OFF. Check the TVA sensor connector X966, the inline harness connector X-941 and the engine ECU connector X-939. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, continue with step 3. 3. Check for an open circuit. Disconnect the TVA sensor connector X966 and the ECU connector X-939. Insert a jumper wire between connector X-939 pin 8 (BK/YE) and pin 53 (GY/BK). Use a multi-meter to check for continuity from the harness side of connector X966 pin 1 (BK/YE) and pin 5 (GY/BK). There should be continuity. A. If there is continuity, leave connectors disconnected. Continue with step 4. B. If there is no continuity, there is an open circuit in the wiring harness. Locate and repair damaged wiring. 4. Check for an open circuit. Insert a jumper wire between connector X-939 pin 37 (TQ/GN) and pin 53 (GY/BK). Use a multi-meter to check for continuity from the harness side of connector X966 pin 3 (TQ/GN) and pin 5 (GY/BK). There should be continuity. A. If there is continuity, leave connectors disconnected. Continue with step 5. B. If there is no continuity, there is an open circuit in the wiring harness. Locate and repair damaged wiring. 5. Check for a short to voltage. Remove the jumper wires. Place the ignition key switch ON. Use a multi-meter to check for voltage from the harness side of connector: X-939 pin 8 (BK/YE) to chassis ground X-939 pin 37(TQ/GN) to chassis ground X-939 pin 53 (GY/BK) to chassis ground There should be no voltage. A. If there is no voltage, the wiring harness is good. Replace the TVA sensor. B. If there is voltage, there is a short to voltage in the wiring harness. Locate and repair damaged wiring.

47538922 29/05/2013

55.8 [55.DTC] / 698

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 699

Electrical systems - FAULT CODES

3831-Throttle Valve Actuator (TVA) - position signal too low Control Module : ECU Context: The engine control unit (ECU) monitors the electrical signal of the diesel fluid contaminant (DFC) for the throttle valve actuator (TVA) position sensor. Cause: The calculated TVA position is below the minimum physical range. Possible failure modes: 1. Faulty wiring 2. Faulty TVA sensor Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Place the ignition key switch OFF. Check the TVA sensor connector X966, the inline harness connector X-941 and the engine ECU connector X-939. Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found, reconnect the wiring harness to the sensor. Continue with step 3. 3. Check for a short to ground. Place the ignition key switch OFF. Disconnect the TVA sensor connector X966 and the ECU connector X-939. Use a multi-meter to check for continuity from the harness side of connector: X-939 pin 8 (BK/YE) to chassis ground X-939 pin 37 (TQ/GN) to chassis ground X-939 pin 53 (GY/BL) to chassis ground There should be no continuity. A. If there is no continuity, the wiring harness is in good condition. Replace the TVA sensor. B. If there is continuity, there is a short circuit to ground condition in the wiring harness. Locate and repair damaged wiring.

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55.8 [55.DTC] / 700

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 701

Electrical systems - FAULT CODES

3834-Throttle Valve Actuator (TVA) - position signal too high Control Module : ECU Context: The engine control unit (ECU) monitors the electrical signal of the throttle valve actuator (TVA) position sensor. Cause: The sensed voltage is higher than 4.75 V. Possible failure modes: 1. Faulty wiring 2. Faulty TVA sensor Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Turn the key switch OFF. Check the wiring harness from the TVA sensor connector X966 to the ECU connector X-939 . Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found. Continue with step 3. 3. Turn the key switch OFF. Disconnect the wiring harness from the TVA sensor at connector X966 and the ECU at connector X-939. Insert a jumper wire between connector X-939 pin 8, wire 393 (BL/YE) and pin 53, wire 419 (GY/BK). Use a multi-meter to check for continuity from the harness side of connector X966 pin 1 and pin 5. There should be continuity. A. If there is continuity, leave connectors disconnected. Continue with step 4. B. If there is no continuity, there is an open circuit in the wiring harness. Locate and repair damaged wiring. 4. Turn the key switch OFF. Insert a jumper wire between connector X-939 pin 53, wire 419 (GY/BL) and pin 37, wire 409 (TQ/GN). Use a multi-meter to check for continuity from the harness side of connector X966 pin 3 and pin 5. There should be continuity. A. If there is continuity, leave connectors disconnected. Continue with step 5. B. If there is no continuity, there is an open circuit in the wiring harness. Locate and repair damaged wiring. 5. Remove the jumper wire. Check for a short to voltage in the wiring harness. Turn the key switch ON. Use a multi-meter to check for voltage from the harness side of connector: X-939 pin 8, wire 393 (BL/YE) to chassis ground X-939 pin 53, wire 419 (GY/BL) to chassis ground X-939 pin 37, wire 409 (TQ/GN) to chassis ground There should be no voltage. A. If there is no voltage, the wiring harness is good. Replace the TVA sensor. B. If there is voltage, there is a short to voltage in the wiring harness. Locate and repair damaged wiring.

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55.8 [55.DTC] / 702

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 703

Electrical systems - FAULT CODES

3835-Throttle Valve Actuator (TVA) - position signal too low Control Module : ECU Context: The engine control unit (ECU) monitors the electrical signal of the throttle valve actuator (TVA) position sensor. Cause: The signal circuit is below 250 mV. Possible failure modes: 1. Faulty wiring 2. Faulty TVA sensor Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Turn the key switch OFF. Check the wiring harness from the TVA sensor connector X966 to the ECU connector X-939 . Inspect all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks. A. If any damage is found, repair or replace connections, pins, or wiring. B. If no damage is found. Continue with step 3. 3. Turn the key switch OFF. Disconnect the wiring harness from the TVA sensor at connector X966 and the ECU at connector X-939. Use a multi-meter to check for continuity from the harness side of connector: X-939 pin 8, wire 393 (BL/YE) to chassis ground X-939 pin 53, wire 419 (GY/BL) to chassis ground X-939 pin 37, wire 409 (TQ/GN) to chassis ground There should be no continuity. A. If there is no continuity, the wiring harness is in good condition. Replace the TVA sensor. B. If there is continuity, there is a short circuit to ground condition in the wiring harness. Locate and repair damaged wiring.

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55.8 [55.DTC] / 704

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 705

Electrical systems - FAULT CODES

3838-Diesel Oxidation Catalyst (DOC) inlet temperature sensor signal too high Control Module : ECU Context: The engine control unit (ECU) has detected the exhaust gas temperature sensor #1 sensed voltage is above 3.59 V. Cause: The exhaust gas temperature sensor #1 signal is shorted to a high voltage source. Possible failure modes: 1. Faulty electrical wiring 2. Faulty sensor 3. Faulty control unit Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Check for a short to voltage source. Place the ignition switch in the OFF position. Disconnect the engine harness from the exhaust gas temp sensor #1 at connector X-946 and from the ECU at connector X-937. Place the ignition switch ON. Use a multi-meter to check for voltage from the engine harness side of connector X-946 pin 1, wire 324 (BR/YE) to chassis ground. There should be no voltage. A. If there is voltage, the short to voltage source is in the engine harness between connector X-946 pin 1, wire 324 (BR/YE) and connector X-937 pin 80, wire 324 (N/Y). Locate and repair the damaged wiring. B. If there is no voltage, leave the connectors disconnected. Continue with step 3. 3. Check for a short to voltage source. Place the ignition switch ON. Use a multi-meter to check for voltage from the engine harness side of connector X-946 pin 2, wire 323 (BR/GN) to chassis ground. There should be no voltage. A. If there is voltage, the short to voltage source is in the engine harness between connector X-946 pin 2, wire 323 (BR/GN) and connector X-937 pin 79, wire 323 (BR/GN). Locate and repair the damaged wiring. B. If there is no voltage, leave the connectors disconnected. Continue with step 4. 4. Check for an open circuit. Place the ignition switch in the OFF position. Use a multi-meter to check for continuity from the engine harness side of connector X-946 pin 2, wire 323 (BR/GN) to connector X-937 pin 79, wire 323 (BR/GN). There should be continuity. A. If there is no continuity, the open circuit is in the engine harness between connector X-946 pin 2, wire 323 (BR/GN) and connector X-937 pin 79, wire 323 (BR/GN). Locate and repair the damaged wiring. B. If there is continuity, leave connectors disconnected. Continue with step 5. 5. Check for an open circuit. Place the ignition switch in the OFF position. Use a multi-meter to check for continuity from the engine harness side of connector X-946 pin 1, wire 324 (BR/YE) to connector X-937 pin 80, wire 324 (BR/YE). There should be continuity. A. If there is no continuity, the open circuit is in the engine harness between connector X-946 pin 1, wire 324 (BR/YE) and connector X-937 pin 80, wire 324 (BR/YE). Locate and repair the damaged wiring. B. If there is continuity, leave connectors disconnected. Continue with step 6. 6. Check the sensor. Make sure the machine is fully cooled down to ambient temperature. Use a multi-meter to measure the resistance on the sensor from pin 1 to pin 2. There should be approximately 175 - 250 ÎŠ. 47538922 29/05/2013

55.8 [55.DTC] / 706

Electrical systems - FAULT CODES

A. If the resistance is within 175 - 250 ÎŠ, try reloading the ECU software. Check to see if the fault code has cleared. If fault code reappears, replace the ECU. B. If the resistance is infinite or 0.0 ÎŠ the sensor has failed. Replace the sensor.

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55.8 [55.DTC] / 707

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 708

Electrical systems - FAULT CODES

3839-Diesel Oxidation Catalyst (DOC) inlet temperature sensor signal too low Control Module : ECU Context: The engine control unit (ECU) has detected the exhaust gas temperature sensor #1 sensed voltage is below 459.40 mV Cause: The exhaust gas temperature sensor #1 signal is shorted to a ground source. Possible failure modes: 1. Faulty electrical wiring 2. Faulty sensor 3. Faulty control unit Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Check for a short to ground source. Place the ignition switch in the OFF position. Disconnect the engine harness from the exhaust gas temp sensor #1 at connector X-946 and from the ECU at connector X-937. Use a multi-meter to check for continuity from the engine harness side of connector X-946 pin 1, wire 324 (BR/YE) to chassis ground. There should be no continuity. A. If there is continuity , the short to ground source is in the engine harness between connector X-946 pin 1, wire 324 (BR/YE) and connector X-937 pin 80, wire 324 (BR/YE). Locate and repair the damaged wiring. B. If there is no continuity, leave the connectors disconnected. Continue with step 3. 3. Check for an open circuit. Place the ignition switch in the OFF position. Use a multi-meter to check for continuity from the engine harness side of connector X-946 pin 2, wire 323 (BR/GN) to connector X-937 pin 79, wire 323 (BR/GN). There should be continuity. A. If there is no continuity, the open circuit is in the engine harness between connector X-946 pin 2, wire 323 (BR/GN) and connector X-937 pin 79, wire 323 (BR/GN). Locate and repair the damaged wiring. B. If there is continuity, leave connectors disconnected. Continue with step 4. 4. Check for an open circuit. Place the ignition switch in the OFF position. Use a multi-meter to check for continuity from the engine harness side of connector X-946 pin 1, wire 324 (BR/YE) to connector X-937 pin 80, wire 324 (BR/YE). There should be continuity. A. If there is no continuity, the open circuit is in the engine harness between connector X-946 pin 1, wire 324 (BR/YE) and connector X-937 pin 80, wire 324 (BR/YE). Locate and repair the damaged wiring. B. If there is continuity, leave connectors disconnected. Continue with step 5. 5. Check the sensor. Make sure the machine is fully cooled down to ambient temperature. Use a multi-meter to measure the resistance on the sensor from pin 1 to pin 2. There should be approximately 175 - 250 ÎŠ. A. If the resistance is within 175 - 250 ÎŠ, try reloading the ECU software. Check to see if the fault code has cleared. If fault code reappears, replace the ECU. B. If the resistance is infinite or 0.0 ÎŠ the sensor has failed. Replace the sensor.

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55.8 [55.DTC] / 709

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

47538922 29/05/2013

55.8 [55.DTC] / 710

Electrical systems - FAULT CODES

3840-Diesel Particulate Filter (DPF) inlet temperature sensor signal too high Control Module : ECU Context: The engine control unit (ECU) has detected the exhaust gas temperature sensor #2 sensed voltage is above 3.59 V. Cause: The exhaust gas temperature sensor #2 signal is shorted to a high voltage source. Possible failure modes: 1. Faulty electrical wiring 2. Faulty sensor 3. Faulty control unit Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Check for a short to voltage source. Place the ignition switch in the OFF position. Disconnect the engine harness from the exhaust gas temp sensor #2 at connector X-945 and from the ECU at connector X-937. Place the ignition switch ON. Use a multi-meter to check for voltage from the engine harness side of connector X-945 pin 1, wire 322 (GN/WH) to chassis ground. There should be no voltage. A. If there is voltage, the short to voltage source is in the engine harness between connector X-945 pin 1, wire 322 (GN/WH) and connector X-937 pin 84, wire 322 (GN/WH). Locate and repair the damaged wiring. B. If there is no voltage, leave the connectors disconnected. Continue with step 3. 3. Check for a short to voltage source. Place the ignition switch ON. Use a multi-meter to check for voltage from the engine harness side of connector X-945 pin 2, wire 320 (BK/WH) to chassis ground. There should be no voltage. A. If there is voltage, the short to voltage source is in the engine harness between connector X-945 pin 2, wire 320 (BK/WH) and connector X-937 pin 83, wire 320 (BK/WH). Locate and repair the damaged wiring. B. If there is no voltage, leave the connectors disconnected. Continue with step 4. 4. Check for an open circuit. Place the ignition switch in the OFF position. Use a multi-meter to check for continuity from the engine harness side of connector X-945 pin 2, wire 320 (BK/WH) to connector X-937 pin 83, wire 320 (BK/WH). There should be continuity. A. If there is no continuity, the open circuit is in the engine harness between connector X-945 pin 2, wire 320 (BK/WH) and connector X-937 pin 83, wire 320 (BK/WH). Locate and repair the damaged wiring. B. If there is continuity, leave connectors disconnected. Continue with step 5. 5. Check for an open circuit. Place the ignition switch in the OFF position. Use a multi-meter to check for continuity from the engine harness side of connector X-945 pin 1, wire 322 (GN/WH) to connector X-937 pin 84, wire 322 (GN/WH). There should be continuity. A. If there is no continuity, the open circuit is in the engine harness between connector X-945 pin 1, wire 322 (GN/WH) and connector X-937 pin 84, wire 322 (GN/WH). Locate and repair the damaged wiring. B. If there is continuity, leave connectors disconnected. Continue with step 6. 6. Check the sensor. Make sure the machine is fully cooled down to ambient temperature. Use a multi-meter to measure the resistance on the sensor from pin 1 to pin 2. There should be approximately 175 - 250 ÎŠ. 47538922 29/05/2013

55.8 [55.DTC] / 711

Electrical systems - FAULT CODES

47538922 29/05/2013

55.8 [55.DTC] / 712

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 713

Electrical systems - FAULT CODES

3841-Diesel Particulate Filter (DPF) inlet temperature sensor signal too low Control Module : ECU Context: The engine control unit (ECU) has detected the exhaust gas temperature sensor #2 sensed voltage is less than 459.40 mV . Cause: The exhaust gas temperature sensor #2 signal is shorted to a ground source. Possible failure modes: 1. Faulty electrical wiring 2. Faulty sensor 3. Faulty control unit Solution: 1. Verify the fault code is still present and in an active state. A. If the fault is no longer active or present, check for an intermittent fault. B. If the fault is still present and active, continue with step 2. 2. Check for a short to ground source. Place the ignition switch in the OFF position. Disconnect the engine harness from the exhaust gas temp sensor #2 at connector X-945 and from the ECU at connector X-937. Use a multi-meter to check for continuity from the engine harness side of connector X-945 pin 1 (GN/WH) to chassis ground. There should be no continuity. A. If there is continuity , the short to ground source is in the engine harness between connector X-945 pin 1, wire 322 (GN/WH) and connector X-937 pin 84, wire 322 (GN/WH). Locate and repair the damaged wiring. B. If there is no continuity, leave the connectors disconnected. Continue with step 3. 3. Check for an open circuit. Place the ignition switch in the OFF position. Use a multi-meter to check for continuity from the engine harness side of connector X-945 pin 2, wire 320 (BK/WH) to connector X-937 pin 83, wire 320 (BK/WH). There should be continuity. A. If there is no continuity, the open circuit is in the engine harness between connector X-945 pin 2, wire 320 (BK/WH) and connector X-937 pin 83, wire 320 (BK/WH). Locate and repair the damaged wiring. B. If there is continuity, leave connectors disconnected. Continue with step 4. 4. Check for an open circuit. Place the ignition switch in the OFF position. Use a multi-meter to check for continuity from the engine harness side of connector X-945 pin 1, wire 322 (GN/WH) to connector X-937 pin 84. There should be continuity. A. If there is no continuity, the open circuit is in the engine harness between connector X-945 pin 1, wire 322 (GN/WH) and connector X-937 pin 84, wire 322 (GN/WH). Locate and repair the damaged wiring. B. If there is continuity, leave connectors disconnected. Continue with step 5. 5. Check the sensor. Make sure the machine is fully cooled down to ambient temperature. Use a multi-meter to measure the resistance on the sensor from pin 1 to pin 2. There should be approximately 175 - 250 ÎŠ. A. If the resistance is within 175 - 250 ÎŠ, try reloading the ECU software. Check to see if the fault code has cleared. If fault code reappears, replace the ECU. B. If the resistance is infinite or 0.0 ÎŠ the sensor has failed. Replace the sensor.

47538922 29/05/2013

55.8 [55.DTC] / 714

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.8 [55.DTC] / 715

Electrical systems - FAULT CODES

3842-Exhaust manifold temperature sensor - signal too high Control Module : ECU Context: The engine control unit (ECU) has detected the inlet turbo temperature sensor sensed voltage is above 3.59 V. Cause: The inlet turbo temperature sensor signal is shorted to a high voltage source. Possible failure modes: 1. Faulty electrical wiring 2. Faulty sensor 3. Faulty control unit Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for Active fault codes: Start and operate machine. A. Fault is not recorded again. OK to return the machine to service. B. Fault code 3842 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-937 and the inline turbine temperature sensor connector X-971 . All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-937 to the inline turbine temperature sensor connector X-971. 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 between the signal wires. (1) Turn the ignition key switch OFF (2) Disconnect ECU connector X-937. Disconnect the inline turbine temperature sensor connector X-971. (3) Fabricate a jumper wire 20 cm (8 in) long. Use the jumper wire to short the inline turbine temperature sensor connector X-971 pin 1 to pin 2. Measure the resistance between the ECU connector X-937 pin 81, wire 325 (BK) and X-937 pin 82, wire 326 (BK/WH). Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is less than 10 ÎŠ. Go to Step 4. B. The resistance is greater than 10 ÎŠ there is an open circuit in the sensor wires. Repair or replace the wires as required. Go to Step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to battery. (1) Disconnect ECU connector X-937. Disconnect the inline turbine temperature sensor connector X-971. (2) Turn the ignition key switch ON.

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55.8 [55.DTC] / 716

Electrical systems - FAULT CODES

(3) Measure the voltage between ECU connector X-937 pin 82, wire 326 (BK/WH) to chassis ground. The voltage should be less than 0.2 V. Wiggle the harness during measurement to reveal an intermittent condition. A. The voltage is less than 0.2 V, go to Step 5. B. The voltage is greater than 0.2 V, the wire is shorted to another voltage source. Repair or replace the wire as required. Go to Step 1 to confirm elimination of the fault. 5. Measure the resistance of the sensor. (1) Turn the ignition key switch OFF (2) Disconnect the inline turbine temperature sensor connector X-971. (3) Measure the resistance between the component side of the inline turbine temperature sensor connector X-971 pin 1 to pin 2. The resistance should be approximately 175 - 250 ÎŠ. A. The resistance is within the specified range. Temporarily replace the ECU and retest. Go to Step 1 to confirm the elimination of the fault. B. The resistance is not within the specified range. Temporarily replace the inline turbine temperature sensor and retest. Go to Step 1 to confirm the elimination of the fault.

47538922 29/05/2013

55.8 [55.DTC] / 717

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18) Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

47538922 29/05/2013

55.8 [55.DTC] / 718

Electrical systems - FAULT CODES

3843-Exhaust manifold temperature sensor - signal too low Control Module : ECU Context: The engine control unit ( ECU ) has detected the inline turbine temperature sensor sensed voltage is less than 459.40 mV. Cause: The inline turbine temperature sensor signal is shorted to a ground source. Possible failure modes: 1. Faulty electrical wiring 2. Faulty sensor 3. Faulty control unit Solution: 1. Verify that the fault code is still active. Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occurrence. (1) Use the Electronic Service Tool to clear all fault codes. (2) To check for Active fault codes: Start and operate machine. A. Fault is not recorded again. OK to return the machine to service. B. Fault code 3843 is recorded again. Go to Step 2. 2. Verify that the wiring and connectors are free of damage. (1) Inspect the ECU connector X-937 and the inline turbine temperature sensor connector X-971 . All connections should be secure, tight, free of corrosion, abrasion and damage. (2) Inspect the harness from the ECU connector X-937 to the inline turbine temperature sensor connector X-971. 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 between the signal wires. (1) Turn the ignition key switch OFF (2) Disconnect ECU connector X-937. Disconnect the inline turbine temperature sensor connector X-971. (3) Measure the resistance between ECU connector X-937 pin 82, wire 326 (BK/WH) to X-937 pin 81, wire 325 (BK). The resistance should be greater than 20,000 ÎŠ Wiggle the harness during measurement to reveal an intermittent condition. A. The resistance is greater than 20,000 ÎŠ. Go to Step 4. B. The resistance is less than 20,000 ÎŠ there is a short circuit between the sensor wires. Repair or replace the wires as required. Go to Step 1 to confirm elimination of fault. 4. Measure the resistance of the signal wire to chassis ground. (1) Turn the ignition key switch OFF. (2) Disconnect ECU connector X-937. Disconnect the inline turbine temperature sensor connector X-971. 47538922 29/05/2013

55.8 [55.DTC] / 719

Electrical systems - FAULT CODES

(3) Measure the resistance between ECU connector X-937 pin 82, wire 326 (BK/WH) 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 between the sensor signal wire and chassis ground. Repair or replace the signal wire as required. Go to Step 1 to confirm elimination of fault. 5. Measure the resistance of the signal wire to chassis ground. (1) Turn the ignition key switch OFF (2) Disconnect the inline turbine temperature sensor connector X-971. (3) Measure the resistance of the inline turbine temperature sensor connector X-971 pin 1 to chassis ground. The resistance should be greater than 20,000 Ω. A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU and retest. Go to Step 1 to confirm the elimination of the fault. B. The resistance is less than 20,000 Ω the sensor has a short circuit to chassis ground. Temporarily replace the sensor and retest. Go to Step 1 to confirm elimination of fault.

47538922 29/05/2013

55.8 [55.DTC] / 720

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18) Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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55.8 [55.DTC] / 721

Electrical systems - FAULT CODES

3852-Lambda sensor - insufficient heater performance Control Module : ECU Context: The heat up of the oxygen sensor is monitored by the ECU. If insufficient heater performance from the oxygen sensor is detected for too long this fault code will occur. Replace the Lambda (oxygen) sensor X-943.

47538922 29/05/2013

55.8 [55.DTC] / 722

Electrical systems - FAULT CODES

3870-CAN-Bus message timeout - BC2EDC1 from ADIC Control Module : ECU NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: The ECU has detected a timeout of BCM2EDC1 CAN message. Possible failure modes: 1. Faulty harness 2. CAN BUS interference 3. Faulty ECU 4. Faulty XCM Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the tractor under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2 2. Check for other CAN related error codes displayed. A. If other error codes are displayed, continue to these tests. B. If no other error codes are displayed, continue to step 3 3. Check all power supplies and grounds to the controllers on the CAN BUS network. A. If a fault is indicated, repair or replace the harness as required. B. If the power supplies and grounds are okay, download the correct levels of controller software. If the fault is still present, remove and replace the ECU.

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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

14 15 17 18

(55.100.DP-C.20.E.14) (55.100.DP-C.20.E.15) (55.100.DP-C.20.E.17) (55.100.DP-C.20.E.18)

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3899-Info: Engine temperature exceeded pre-warn level T5.

Control Module : ECU Context: This fault is caused when the engine temperature is getting to high. This fault can be caused by a cooling system problem, high environmental temperatures or due to heavy engine use. If the environmental temperature is not too high and the machine has not been used heavily, let the engine cool down. Then check the cooling system has the correct amount of coolant. Make sure the radiator is not clogged or is restricted of air flow. Also, check the thermostat is not stuck. Once everything has been checked, if everything is correct, erase the fault code.

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3900-Info: Engine temperature exceeded warn level Control Module : ECU Context: This fault is caused when the engine temperature is getting to high. This fault can be caused by a cooling system problem, high environmental temperatures or due to heavy engine use. If the environmental temperature is not too high and the machine has not been used heavily, let the engine cool down. Then check the cooling system has the correct amount of coolant. Make sure the radiator is not clogged or is restricted of air flow. Also, check the thermostat is not stuck. Once everything has been checked, if everything is correct, erase the fault code.

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3910-High pressure pump solenoid valve - intermittent connection to ECU Control Module : ECU Context: The engine control unit (ECU) has detected a loose contact in the wiring of the metering unit. This can result in a malfunction of the metering unit and lead to fuel pressure oscillations. Check all connections of fuel metering unit connector X-970 and the ECU connector X-939 are good. Remove connectors X-970, X-939 and check that the pins are not bent or corroded. Check the wiring harness is not damaged. If any damage or issues are found, repair/replace damaged connectors, or wiring. Use a multi-meter to measure the resistance of the fuel metering solenoid connector X-970 from pin 1 to pin 2. There should be approximately 3.2 ÎŠ. If the coil resistance is not correct, replace the fuel metering unit.

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Wire harnesses - Electrical schematic frame 19 (55.100.DP-C.20.E.19)

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Index Electrical systems - 55 FAULT CODES - DTC 1002-Radar sensor - disconnected or speed too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 1003-Radar sensor and transmission output speed sensor - speed difference too high . . . . . . . . . . . . . . . . . . . . . 83 1004-Transmission output speed sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 1006-Hitch slip control potentiometer - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 1007-Hitch slip control potentiometer - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 1008-Raise/work switch failure (command arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1009-Hitch position control switches - implausible signals or signal at key on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 1010-Hitch height limit potentiometer - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 1011-Hitch height limit potentiometer - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 1012-Hitch drop rate potentiometer - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 1013-Hitch drop rate potentiometer - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 1014-Right-hand draft pin sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 1015-Right-hand draft pin sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 1016-Left-hand draft pin sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 1017-Left-hand draft pin sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 1018-Draft pin sensors - both signals too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 1019-8 V reference voltage for draft pin sensors - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 1020-8 V reference voltage for draft pin sensors - voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 1021-Hitch sensitivity control potentiometer - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 1022-Hitch sensitivity control potentiometer - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 1023-Hitch electronic control panel - disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 1024-Hitch position sensor - not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 1025-Hitch position control potentiometer - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 1026-Hitch position control potentiometer - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 1027-Hitch position sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 1028-Hitch position sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 1029-Hitch control solenoid valves - disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 1030-Hitch electronic control panel - ground disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 1031-Chassis harness - disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 1032-Hitch draft control potentiometer - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 1033-Hitch draft control potentiometer - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 1049-CAN-Bus signal fault - transmission output speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 1053-5 V reference voltage for Electronic Draft Control (EDC) - voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . 142 1054-5 V reference voltage for Electronic Draft Control (EDC) - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . 144

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1063-Lower solenoid valve - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 1064-Raise solenoid valve - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 1065-Lower solenoid valve - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 1066-Raise solenoid valve - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 1067-Supply voltage for hitch control solenoid valves - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 1068-Electronic Draft Control (EDC) - calibration fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 1070-Electronic Draft Control (EDC) - ram configuration not set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 14015-5V reference voltage - too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 14016-5V reference voltage - too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 14021-Cranking line - shorted to +12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 14022-Cranking line - shorted to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 14051-Fuel level sensor - short circuit to supply voltage or open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 14052-Fuel level sensor - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 14058-Seat switch closed over 25 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 14061-Air brake pressure short to Vcc or option set but sensor not connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 14093-Seat switch signal short to + 12V or open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 14094-Seat switch - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 14100-Air brake option not configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 14200-Battery isolator switch closed to battery at Key ON for more than 30 seconds . . . . . . . . . . . . . . . . . . . . . . . 72 14900-CCU module missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 14901-Engine controller missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 14908-TECU module missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 2001-Shuttle too fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 2005-Creeper engage fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2006-Radar sensor - disconnected or speed too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 2011-Clutch pedal sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 2012-Clutch pedal sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 2013-Upshift and downshift switch ON error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2016-Creeper solenoid error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 2024-At least one synchroniser require calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 2026-Engine speed - too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 2027-Engine speed no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2037-Clutch pedal switch - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 2038-Clutch 4 solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 2039-Clutch 4 solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 2040-Clutch 3 solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 2041-Clutch 3 solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 2042-Clutch 2 solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 2043-Clutch 2 solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 2044-Clutch 1 solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 2045-Clutch 1 solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 2047-Clutch pedal switch set too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

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2048-Clutch pedal switch set too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 2049-Wheel speed sensor - short to ground or open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 2050-Transmission output speed sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 2051-Transmission oil temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 2052-Transmission oil temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 2053-5V reference voltage - voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 2054-5V reference voltage - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 2055-Transmission output speed sensor - implausible speed drop detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 2056-Low Range switch open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 2057-High Range switch open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 2059-Shuttle lever - implausible signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 2061-Forward/reverse synchroniser potentiometer signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 2062-Forward/reverse synchroniser potentiometer signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 2063-Forward synchroniser did not engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 2064-Reverse synchroniser did not engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 2065-Forward synchroniser solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 2066-Reverse synchroniser solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 2067-Forward synchroniser solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 2068-Reverse synchroniser solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 2070-Shuttle lever forward switch - voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 2071-Shuttle lever forward switch - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 2072-Shuttle lever reverse switch - voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 2073-Shuttle lever reverse switch - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 2081-4/5 range synchroniser potentiometer - signal high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 2082-4/5 range synchroniser potentiometer - signal low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 2083-1-4 range synchroniser engaged error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 2084-5-8 range synchroniser engaged error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 2085-1-4 range synchroniser solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 2086-5-8 range synchroniser solenoid - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 2087-1-4 range synchroniser solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 2088-5-8 range synchroniser solenoid - short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 2089-CAN-Bus - invalid engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 2090-CAN-Bus - ADIC absent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 2091-Clutch 3 not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 2092-Clutch 4 not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 2095-Clutch 1 not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 2096-Clutch 2 not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 2110-Voltage from Shuttle lever Neutral switch too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 2111-Voltage from Shuttle lever Neutral switch too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 3001-Foot throttle position sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 3002-Foot throttle position sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 3003-Foot throttle position sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

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3007-Engine coolant temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 3008-Engine coolant temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 3010-Intake air pressure and temperature sensor - temperature signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . 360 3011-Intake air pressure and temperature sensor - temperature signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 3015-Fuel temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368 3016-Fuel temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 3019-Intake air pressure and temperature sensor - pressure signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373 3024-Air pressure sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376 3025-Air pressure sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377 3027-Engine oil pressure switch - defect fault check for plausibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378 3037-Boost pressure sensor - signal low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 3038-Constant engine speed selector switch - signals not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 3052-ECU supply voltage - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 3059-Main relay ECU - stuck relay fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 3063-Injector cylinder 1 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 3071-Injector cylinder 3 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393 3079-Injector cylinder 2 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396 3083-Injector cylinder 4 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399 3088-Crankshaft sensor - no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402 3089-Crankshaft sensor - invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406 3090-Camshaft sensor - no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 3091-Camshaft sensor - invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412 3093-Crankshaft sensor and camshaft sensor - offset between speed signals too high . . . . . . . . . . . . . . . . . . . . 415 3096-CAN-Bus - ECU in bus-off state or CAN-Bus fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 3102-Common rail pressure sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 3104-Common rail relief valve - open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 3106-Pressure relief valve reached maximum allowed opening count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 3107-High pressure pump solenoid valve - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 3108-High pressure pump solenoid valve - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426 3112-Common rail pressure sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 3126-Hand throttle - signal 1 too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430 3127-Hand throttle - signal 1 too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432 3137-High pressure pump solenoid valve - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 3139-High pressure pump solenoid valve - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 3140-High pressure pump solenoid valve - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438 3146-Water in fuel sensor - water detected or faulty sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 3157-CAN-Bus - ECU absent or engine dataset not available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442 3166-Fuel heater relay - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 3167-Fuel heater relay - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446 3168-Fuel heater relay - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448 3169-Fuel heater relay - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 3179-CAN-Bus message timeout - BC2EDC2 from ADIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452

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3180-CAN-Bus message timeout - VCM2EDC from ADIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 3188-Injector cylinder 1 - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456 3192-Injector cylinder 2 - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459 3196-Injector cylinder 3 - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462 3200-Injector cylinder 4 - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465 3210-Injection bank 1 - short circuit on injection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468 3218-Injection bank 2 - short circuit on injection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472 3283-Sensor supply voltage 2 - voltage out of valid range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476 3285-Sensor supply voltage 3 - voltage out of valid range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478 3293-Fuel Metering Unit: maximum positive deviation of rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3301-High pressure pump solenoid valve - maximum negative rail pressure deviation exceeded . . . . . . . . . . . . 480 3309-High pressure pump solenoid valve - maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481 3334-CAN-Bus message timeout - TSC1-PE from CCU (when active) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482 3335-CAN-Bus message timeout - TSC1-PE from CCU (when inactive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484 3338-CAN-Bus message timeout - TSC1-VE from CCU (when inactive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486 3339-CAN-Bus message timeout - TSC1-VE from CCU (when active) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488 3358-CAN-Bus message timeout - transmit EEC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 3375-Constant engine speed increase/decrease switch - signals not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . 492 3377-CRPM switches present but function not enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495 3402-Rail pressure sensor: Maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496 3405-Turbocharger power stage - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497 3406-Turbocharger power stage - temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 3408-Lambda sensor - oxygen concentration too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503 3409-Engine oil pressure switch - oil pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506 3410-Throttle Valve Actuator (TVA) - positive position deviation limit exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . 509 3411-Throttle Valve Actuator (TVA) - negative position deviation limit exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . 511 3414-Glow plug of cylinder 1 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 3415-Glow plug of cylinder 3 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515 3416-Glow plug of cylinder 4 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517 3417-Glow plug of cylinder 2 - short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519 3418-Turbocharger power stage - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 3419-Turbocharger power stage - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524 3425-Turbocharger - boost pressure deviation too high at intake air pressure and temperature sensor . . . . . . . 527 3426-Diesel Particulate Filter (DPF) - level 1 reached . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528 3428-Differential pressure sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529 3432-Exhaust Gas Recirculation (EGR) - inducement warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531 3435-Diesel Particulate Filter (DPF) - inducement warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532 3517-Inlet air temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533 3518-Inlet air temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535 3648-Turbocharger - boost pressure deviation too high at intake air pressure and temperature sensor . . . . . . . 537 3650-Battery voltage - voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538 3651-Battery voltage - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540

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3652-CAN-Bus - bus-off state of node A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542 3657-CAN-Bus message timeout - CM1BC from ADIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544 3663-Exhaust Gas Recirculation (EGR) - command saturation over higher limit . . . . . . . . . . . . . . . . . . . . . . . . . . 546 3664-Exhaust Gas Recirculation (EGR) - command saturation over lower limit . . . . . . . . . . . . . . . . . . . . . . . . . . . 548 3665-Exhaust Gas Recirculation (EGR) valve actuator - positive position deviation limit exceeded . . . . . . . . . . 550 3666-Exhaust Gas Recirculation (EGR) valve actuator - negative position deviation limit exceeded . . . . . . . . . 552 3667-Exhaust Gas Recirculation (EGR) valve actuator - open circuit at power stage . . . . . . . . . . . . . . . . . . . . . . 554 3668-Exhaust Gas Recirculation (EGR) valve actuator - over-temperature at power stage . . . . . . . . . . . . . . . . . 557 3669-Exhaust Gas Recirculation (EGR) valve actuator - short circuit to battery on Out1 of power stage . . . . . . 560 3670-Exhaust Gas Recirculation (EGR) valve actuator - short circuit to battery on Out2 of power stage . . . . . . 562 3671-Exhaust Gas Recirculation (EGR) valve actuator - short circuit to ground on Out1 of power stage . . . . . . 564 3672-Exhaust Gas Recirculation (EGR) valve actuator - short circuit to ground on Out2 of power stage . . . . . . 567 3673-Exhaust Gas Recirculation (EGR) valve actuator - short circuit at power stage . . . . . . . . . . . . . . . . . . . . . . 570 3674-Exhaust Gas Recirculation (EGR) valve actuator - under-voltage at power stage . . . . . . . . . . . . . . . . . . . . 573 3675-Long time EGR valve drift at closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574 3676-Exhaust Gas Recirculation (EGR) valve actuator - position sensor voltage too high . . . . . . . . . . . . . . . . . . 575 3677-Exhaust Gas Recirculation (EGR) valve actuator - position sensor voltage too low . . . . . . . . . . . . . . . . . . . 578 3688-Water in fuel sensor - water in fuel detected or defective sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581 3689-Glow plug control module - faulty diagnostic data transmission or protocol fault . . . . . . . . . . . . . . . . . . . . . . 583 3691-Glow plug control module - open circuit at power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586 3692-Glow plug control module - over-temperature at power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588 3693-Glow plug control module - short circuit to battery at power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591 3694-Glow plug control module - short circuit to ground at power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594 3707-Lambda sensor - open circuit at the nernst cell pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597 3708-Lambda sensor - open circuit at the pump current pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 3709-Lambda sensor - open circuit at the virtual ground pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603 3710-Lambda sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606 3711-Lambda sensor - short circuit to battery at heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609 3712-Lambda sensor - short circuit to ground at heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612 3713-Lambda sensor - open circuit at heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617 3713-Lambda sensor: Open load error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615 3714-Lambda sensor - oxygen ratio signal too high during calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619 3715-Lambda sensor - oxygen ratio signal too low during calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622 3716-Lambda sensor - oxygen ratio signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625 3720-Lambda sensor - supply voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627 3722-Lambda sensor - calculated temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629 3723-Lambda sensor - calculated temperature too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631 3724-Lambda sensor - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633 3725-Lambda sensor - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635 3735-High pressure pump metering solenoid valve - over-temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637 3736-Lambda sensor - oxygen ratio out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639 3737-Lambda sensor - over-temperature at heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640

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3762-Level 2 monitoring - sensor supply voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642 3763-Level 2 monitoring - sensor supply voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644 3764-Main relay ECU - early opening fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646 3790-Diesel Particulate Filter (DPF) - flow resistance exceeded maximum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . 649 3794-Intake air pressure and temperature sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652 3795-Intake air pressure and temperature sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655 3796-Diesel particulate filter pressure sensor hose line error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3797-Differential pressure sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658 3798-Differential pressure sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661 3801-Exhaust manifold pressure sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664 3802-Exhaust manifold pressure sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667 3810-Common rail pressure sensor - intermittent signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 670 3818-Throttle Valve Actuator (TVA) - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 672 3819-Throttle Valve Actuator (TVA) - over-current at power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675 3820-Throttle Valve Actuator (TVA) - over-temperature at power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678 3821-Throttle Valve Actuator (TVA) - short circuit to battery at Out1 of power stage . . . . . . . . . . . . . . . . . . . . . . . 681 3822-Throttle Valve Actuator (TVA) - short circuit to battery at Out2 of power stage . . . . . . . . . . . . . . . . . . . . . . . 683 3823-Throttle Valve Actuator (TVA) - short circuit to ground at Out1 of power stage . . . . . . . . . . . . . . . . . . . . . . . 685 3824-Throttle Valve Actuator (TVA) - short circuit to ground at Out2 of power stage . . . . . . . . . . . . . . . . . . . . . . . 688 3825-Throttle Valve Actuator (TVA) - short circuit at power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691 3826-Throttle Valve Actuator (TVA) - temperature dependent over-current at power stage . . . . . . . . . . . . . . . . . 694 3827-Throttle Valve Actuator (TVA) - under-voltage at power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 697 3830-Throttle Valve Actuator (TVA) - position signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698 3831-Throttle Valve Actuator (TVA) - position signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 3834-Throttle Valve Actuator (TVA) - position signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702 3835-Throttle Valve Actuator (TVA) - position signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704 3838-Diesel Oxidation Catalyst (DOC) inlet temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . 706 3839-Diesel Oxidation Catalyst (DOC) inlet temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . 709 3840-Diesel Particulate Filter (DPF) inlet temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 3841-Diesel Particulate Filter (DPF) inlet temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714 3842-Exhaust manifold temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716 3843-Exhaust manifold temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719 3852-Lambda sensor - insufficient heater performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722 3870-CAN-Bus message timeout - BC2EDC1 from ADIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 3899-Info: Engine temperature exceeded pre-warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 T5.

3900-Info: Engine temperature exceeded warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726 3910-High pressure pump solenoid valve - intermittent connection to ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727 4500-Electro Hydraulic Remote valve (EHR) front 1 - no control message received . . . . . . . . . . . . . . . . . . . . . . . 266 4501-Electro Hydraulic Remote valve (EHR) front 1 - control message not plausible . . . . . . . . . . . . . . . . . . . . . . 268 4502-Electro Hydraulic Remote valve (EHR) front 1 - EEPROM fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 4503-Electro Hydraulic Remote valve (EHR) front 1 - switched to failsafe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 4504-Electro Hydraulic Remote valve (EHR) front 1 - under-voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

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4505-Electro Hydraulic Remote valve (EHR) front 1 - over-voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 4506-Electro Hydraulic Remote valve (EHR) front 1 - spool movement too low . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 4507-Electro Hydraulic Remote valve (EHR) front 1 - spool movement too high . . . . . . . . . . . . . . . . . . . . . . . . . . 276 4508-Electro Hydraulic Remote valve (EHR) front 1 - float position not reached . . . . . . . . . . . . . . . . . . . . . . . . . . 277 4509-Electro Hydraulic Remote valve (EHR) front 1 - manually operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 4511-Electro Hydraulic Remote valve (EHR) front 1 - potentiometer faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 4512-Electro Hydraulic Remote valve (EHR) front 1 - unable to reach neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 4513-Electro Hydraulic Remote valve (EHR) front 1 - spool not in neutral at key on . . . . . . . . . . . . . . . . . . . . . . . 281 4514-Electro Hydraulic Remote valve (EHR) front 2 - no control message received . . . . . . . . . . . . . . . . . . . . . . . 282 4515-Electro Hydraulic Remote valve (EHR) front 2 - control message not plausible . . . . . . . . . . . . . . . . . . . . . . 284 4516-Electro Hydraulic Remote valve (EHR) front 2 - EEPROM fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 4517-Electro Hydraulic Remote valve (EHR) front 2 - switched to failsafe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 4518-Electro Hydraulic Remote valve (EHR) front 2 - under-voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 4519-Electro Hydraulic Remote valve (EHR) front 2 - over-voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 4520-Electro Hydraulic Remote valve (EHR) front 2 - spool movement too low . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 4521-Electro Hydraulic Remote valve (EHR) front 2 - spool movement too high . . . . . . . . . . . . . . . . . . . . . . . . . . 292 4522-Electro Hydraulic Remote valve (EHR) front 2 - float position not reached . . . . . . . . . . . . . . . . . . . . . . . . . . 293 4523-Electro Hydraulic Remote valve (EHR) front 2 - manually operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 4525-Electro Hydraulic Remote valve (EHR) front 2 - potentiometer faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 4526-Electro Hydraulic Remote valve (EHR) front 2 - unable to reach neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 4527-Electro Hydraulic Remote valve (EHR) front 2 - spool not in neutral at key on . . . . . . . . . . . . . . . . . . . . . . . 297 4564-EHR joystick - no communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 5001-Rear PTO brake solenoid error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 5005-Rear PTO brake switch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 5008-Rear PTO clutch solenoid - open circuit error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 5027-Rear PTO speed sensor - open circuit error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 5033-Rear PTO cab normally closed switch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 5034-Rear PTO fender switch - open circuit / short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 5035-Rear PTO fender switch - input short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 5037-Rear PTO cab switch normally open error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 5043-Rear PTO fender switch stuck on error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 5044-Rear PTO speed sensor - short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 5045-Ground speed PTO switch open / short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 5046-Ground speed PTO switch short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 5047-Ground speed PTO configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 5098-Rear PTO fender switch option not enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 5099-Rear PTO Auto PTO not enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 6020-FWD (four wheel drive) command switch fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 6023-FWD solenoid short to ground or open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 7014-Differential lock command switch error - switch disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 7017-Differential lock short to ground or open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 8008-Front PTO solenoid - open circuit or short to VBat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

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8033-Front PTO cab normally closed switch - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 8037-Front PTO cab normally open switch - stuck closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 8099-Front PTO option not enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 CH-HOT OIL WARNING: displayed above 105 degress C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 CL-COLD OIL WARNING: displayed below 60 degrees C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 U147-Synchroniser cannot be engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 U148-Range lever not in the high range position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 U17-Seat switch not activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 U19-Oil temperature below 10Â°C, calibration not allowed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 U20-Handbrake is not set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 U21-ERPM is below 1050, increase throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 U22-ERPM is above 1350, reduce throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 U23-Shuttle lever is in neutral, shift lever to forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 U26-Clutch pedal is not up, release clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 U27-C3 calibration value is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 U29-C4 calibration value is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 U31-Wheel speed sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 U32-C1 calibration value is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 U34-C2 calibration value is too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 U36-Max allowed clutch calibration value exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 U37-Synchroniser potentiometer signal is out of range for the reverse position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 U38-Synchroniser potentiometer signal is out of range for the forward position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 U39-Synchroniser did not move toward reverse, even at maximum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 U40-Synchroniser did not move toward forward, even at maximum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 U41-Synchroniser pot signal is out of range for the 4 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 U42-Synchroniser pot signal is out of range for the 5 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 U43-Synchroniser did not move toward 4, even at max pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 U44-Synchroniser did not move toward 5, even at max pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 U82-No 12VD: no power for C3 and C4 solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47538922 29/05/2013 EN

SERVICE MANUAL Platform, cab, bodywork, and decals

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

47538922 29/05/2013

Contents Platform, cab, bodywork, and decals - 90

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 T5.105 ElectroCommand , T5.115 ElectroCommand , T5.95 ElectroCommand

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Platform, cab, bodywork, and decals - 90 Cab - 150

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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90.1 [90.150] / 1

Contents Platform, cab, bodywork, and decals - 90 Cab - 150

SERVICE Cab Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

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Platform, cab, bodywork, and decals - Cab

Cab - Remove T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

Remove the retainer (1), lift the RH steps, open the battery compartment using the knob (2) and disconnect the negative battery cable.

MOIL12TR00670AA

SEZ21CAP4A-7

MOIL12TR00671AA

Remove the RH and LH lower mudguard extension (1).

Remove the hood as described in the operation (see Hood - Remove (90.100))

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Platform, cab, bodywork, and decals - Cab

Remove the fixing bolts (1) and detach the engine left-hand side panel (2). Carry out the same operation for the rightâ&#x2C6;&#x2019;hand side panel too.

MOIL12TR00672AA

MOIL12TR00673AA

MOIL12TR00674AA

MOIL12TR00675AA

Recover the refrigerant from the system via the connections (1) and (2) using the specific tool 380000315.

Detach the two air-conditioning pipes (1) on the cab.

Loosen the union of the cab heater radiator coolant return pipe, drain and collect the engine coolant.

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Platform, cab, bodywork, and decals - Cab

10.

11.

12.

Disconnect the cab heating pipes (1) and remove any fixing elements.

MOIL12TR00676AA

WLAPL4S90C118A

Disconnect the pipelines to the power steering cylinder (1) , the supply to the pump (2) and, from the left-hand side, the power steering outlet.

Mark and detach the range control tie rod (1).

MOIL12TR00677AA

WLAPL4S90C120A

Mark and detach the tie-rods of the joystick governing the ventral spool valves (1) , where applicable.

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Platform, cab, bodywork, and decals - Cab

13.

14.

15.

16.

On the rear LH of the transmission, disconnect the power takeâ&#x2C6;&#x2019;off gearbox cable (1), where applicable.

WLAPL4S90C121A

MOIL12TR00678AA

WLAPL4S90C123A

MOIL12TR00679AA

On the rear RH of the transmission, disconnect the synchronised power takeâ&#x2C6;&#x2019;off tie rod cable (1), where applicable.

Detach the tie-rods (1) from the rear spool valves.

Remove the board and hatch underneath and detach the brake pipes (1). Fit plugs on the pipes to prevent the brake liquid from leaking out.

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Platform, cab, bodywork, and decals - Cab

17.

18.

19.

20.

From the rear, disconnect the following connections: •

Cab/transmission earth cable

•

Transmission cable/main cable

•

Electronic lift cable on transmission

•

Third valve Diverter cable

•

Optional transmission cable (creeper and EHR valves)

MOIL12TR00680AA

MOIL12TR00681AA

MOIL12TR00682AA

MOIL12TR00683AA

From the front, disconnect the following connections: •

Cab/engine splitting cable

•

Front loader 7-pin socket cable

•

Cab power splitting cable

•

Oil tank cable

Place the tool (1) inside the cab and connected it to the hoist using ropes or chains and tension them slightly so that the weight of the cab does not weigh down on the dampers.

Disconnect the struts (1) on both sides of the tractor, unhook the safety rope (2) only on the RH side.

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Platform, cab, bodywork, and decals - Cab

21.

22.

23.

Disconnect the LH rear stabiliser (1).

MOIL12TR00684AA

MOIL12TR00685AA

WLAPL4S90C131A

Remove the screws from the front RH and LH strut system (1).

Slowly raise the cab, checking there are no parts still connected or interfering with the engine or with the transmission, remove the cab (1) and put it down on a wooden base.

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Platform, cab, bodywork, and decals - Cab

Cab - Install T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

Pick up the cab (1) from the wooden base, transfer and lower it slowly onto the tractor body, carefully checking there are no cables or pipes that get in the way of the engine or transmission to prevent them getting damaged.

WLAPL4S90C131A

MOIL12TR00682AA

MOIL12TR00681AA

Tighten the cab fixing screws keeping to the following tightening sequence: 1.

RH rear strut.

LH front nut.

LH rear strut.

RH rear nut.

LH rear tie-rod.

Remove the cab lifting tool (1), working from inside the cab and detach it from the hoist.

From the front, connect the following connections: •

Cab/engine splitting cable.

•

Front loader 7-pin socket cable.

•

Cab power splitting cable.

•

Oil tank cable.

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Platform, cab, bodywork, and decals - Cab

From the rear, connect the following connections: •

Earth Cable.

•

Transmission cable.

•

Lifter cable.

•

Diverter cable.

•

Optional transmission cable.

MOIL12TR00680AA

MOIL12TR00679AA

WLAPL4S90C123A

MOIL12TR00678AA

Connect the brake pipes (1), reassemble the hatch and then the board.

Connect the rear control valve tie-rods (1) and make the necessary adjustments (see Remote control valve control lever - Adjust (35.204))

On the left of the transmission, in the direction of the synchronized power take−off lever, reconnect the synchronized power take−off tie-rod cable (1), where applicable and make the necessary adjustments (see Synchronized Power Take-Off (PTO) controls - Adjust (31.104)).

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Platform, cab, bodywork, and decals - Cab

10.

11.

12.

On the rear LH of the transmission reconnect the power takeâ&#x2C6;&#x2019;off gearbox cable (1), where applicable and make the necessary adjustments (see Power Take-Off (PTO) speed rate selector - Adjust (31.104)).

WLAPL4S90C121A

WLAPL4S90C120A

Reconnect the ventral control valve joystick tie-rods (1), where applicable and make the necessary adjustments (see Remote control valve control lever - Adjust (35.204)).

Reconnect the range control tie-rod (1) and make the necessary adjustments (see Transmission control levers - Adjust (21.134)).

MOIL12TR00677AA

WLAPL4S90C118A

Reconnect the pipes to the power steering cylinder (1), the power to the pump (2), and from the LH side the power steering exhaust.

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Platform, cab, bodywork, and decals - Cab

13.

14.

15.

16.

Reconnect the cab heating pipes (1), and refit any fixing elements.

MOIL12TR00676AA

MOIL12TR00675AA

MOIL12TR00674AA

MOIL12TR00673AA

Screw the union of the cab heater radiator coolant return pipe, fill the radiator with engine coolant.

Reconnect the two air-conditioning pipes (1) on the cab.

From the control unit, fill the conditioning system through the couplings (1) and (2) using the special tool 380000315

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Platform, cab, bodywork, and decals - Cab

17.

Refit the two side panels covering the engine (2) and the relevant fixing bolts (1).

18.

Fit the hood back on (see Hood - Install (90.100)).

19.

Fit the RH and LH lower mudguard extension (1).

20.

21.

MOIL12TR00672AA

MOIL12TR00671AA

SEZ21CAP4A-7

Raise the rear of the tractor with a hydraulic jack, fit the two rear wheels back on and tighten the fixing nuts. Lower the tractor.

Reconnect the negative battery cable.

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Index Platform, cab, bodywork, and decals - 90 Cab - 150 Cab - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

Cab - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

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90.1 [90.150] / 14

Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

T5.105 ElectroCommand T5.115 ElectroCommand T5.95 ElectroCommand

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90.2 [90.100] / 1

Contents Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

SERVICE Hood Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Remove T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

Open the hood by pulling the lever on the left of the hood (1) , raise the hood (2) and disconnect the battery cable.

WLAPL4S90C132A

WLAPL4S90C134A

WLAPL4S90C136A

WLAPL4S90C137A

Disconnect the connection of the front lights cable (1)

Insert the lifting sling (1)

Extract the retaining clip and detach the gas lift cylinder (1) , after which remove the 4 nuts of the hood hinging (2) .

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Platform, cab, bodywork, and decals - Engine hood and panels

Remove the hood assembly (1).

WLAPL4S90C139A

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90.2 [90.100] / 4

Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Install T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

Insert the lifting sling (1) on the hood.

WLAPL4S90C136A

WLAPL4S90C137A

WLAPL4S90C134A

Reconnect the rear hood hinge support and tighten the four fixing screws (2), connect the hood lifting gas cylinder and reconnect the retaining spring (1).

Reconnect the front lights cable connection (1) and the battery negative cable.

Close the bonnet.

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Index Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100 Hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

Hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.95 ElectroCommand INT, T5.95 ElectroCommand WE, T5.95 ElectroCommand NA, T5.105 ElectroCommand INT, T5.105 ElectroCommand WE, T5.105 ElectroCommand NA, T5.115 ElectroCommand INT, T5.115 ElectroCommand WE, T5.115 ElectroCommand NA

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90.2 [90.100] / 6

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90.2 [90.100] / 7

CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47538922 29/05/2013 EN

SPECIAL TOOL INDEX Genuine 380200011 [Air Conditioning Compressor Drive Belt Installer] 380200011 [Air Conditioning Compressor Drive Belt Installer] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 380000315 [Recovery And Rrecharge Portable System (For Discharging And Recovering Of The Refrigerant)] 380000315 [Recovery And Rrecharge Portable System (For Discharging And Recovering Of The Refrigerant)] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 380001116 [Transmission Lifting Eyebolts] 380000569 [Tractor Separation Trolley] 380001147 [Bypass Connector] 380000492 [7/16 UNF Male Quick Release Adapter] 380001146 [90Â° Quick Release Fitting Adapter (M8 x 1mm Male)] 380000552 [Pressure Gauge 0 - 40 Bar] 380000543 [Hydraulic Test Quick Release Coupler (female) 1/4 NPTF] 380000492 [7/16 UNF Male Quick Release Adapter] 380000551 [Pressure Gauge (0 - 10 Bar)] 380000543 [Hydraulic Test Quick Release Coupler (female) 1/4 NPTF] 380000544 [Adaptor 1/8 NPT Fitting to Attach Hose 380000545 to Gauge] 380000492 [7/16 UNF Male Quick Release Adapter] 380000552 [Pressure Gauge 0 - 40 Bar]

Reference

PAGE

Engine - Install

10.1 / 5

Engine - Install

10.1 / 6

Engine - Install

10.1 / 6

Engine - Install

10.1 / 7

Engine - Install

10.1 / 7

Engine - Install

10.1 / 7

Engine - Install

10.1 / 9

Engine - Remove

10.1 / 11

Engine - Remove

10.1 / 18

Engine - Remove

10.1 / 18

Semi-Powershift transmission - Remove

21.1 / 41

Semi-Powershift transmission - Remove

21.1 / 41

Semi-Powershift transmission - Pressure test

21.1 / 53

Semi-Powershift transmission - Pressure test

21.1 / 53

Semi-Powershift transmission - Pressure test

21.1 / 53

Semi-Powershift transmission - Pressure test

21.1 / 54

Semi-Powershift transmission - Pressure test

21.1 / 54

Semi-Powershift transmission - Pressure test

21.1 / 54

Semi-Powershift transmission - Pressure test

21.1 / 54

Semi-Powershift transmission - Pressure test

21.1 / 54

Semi-Powershift transmission - Pressure test

21.1 / 54

Semi-Powershift transmission - Pressure test

21.1 / 60

Semi-Powershift transmission - Pressure test

21.1 / 60

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Genuine 380000543 [Hydraulic Test Quick Release Coupler (female) 1/4 NPTF] 380001155 [DCommand C1/C2/C3/C4 Clutch Piston Spring Compressor] 380001150 [PShift C1/C2 Clutch Drum Seal Guide] 380001148 [Handle] 380200316 [Pshift C1/C2/C3/C4 sizing guide] 380001150 [PShift C1/C2 Clutch Drum Seal Guide] 380200316 [Pshift C1/C2/C3/C4 sizing guide] 380001148 [Handle] 380200315 [Clutch Piston Seal Installer ] 380001151 [PShift Clutch Pistons Installer] 380200315 [Clutch Piston Seal Installer ] 380001151 [PShift Clutch Pistons Installer] 380001151 [PShift Clutch Pistons Installer] 380200315 [Clutch Piston Seal Installer ] 380001155 [DCommand C1/C2/C3/C4 Clutch Piston Spring Compressor] 380001155 [DCommand C1/C2/C3/C4 Clutch Piston Spring Compressor] 380001149 [PShift C3/C4 Clutch Drum Seal Guide] 380200316 [Pshift C1/C2/C3/C4 sizing guide] 380001148 [Handle] 380001149 [PShift C3/C4 Clutch Drum Seal Guide] 380200316 [Pshift C1/C2/C3/C4 sizing guide] 380001148 [Handle] 380001152 [DCommand C3/C4 Clutch Piston Installer] 380001151 [PShift Clutch Pistons Installer] 380001152 [DCommand C3/C4 Clutch Piston Installer] 380001151 [PShift Clutch Pistons Installer] 380001155 [DCommand C1/C2/C3/C4 Clutch Piston Spring Compressor] 380002598 [Transmission Synchroniser Adjuster] 380000268 [Bevel Pinion Ring Nut Wrench]

Reference

PAGE

Semi-Powershift transmission - Pressure test

21.1 / 60

Clutch - Disassemble - Front section disassembly.

21.3 / 13

Clutch - Assemble - C1/C2 Clutches.

21.3 / 20

Clutch - Assemble - C1/C2 Clutches. Clutch - Assemble - C1/C2 Clutches.

21.3 / 20 21.3 / 20

Clutch - Assemble - C1/C2 Clutches.

21.3 / 20

Clutch - Assemble - C1/C2 Clutches.

21.3 / 20

Clutch - Assemble - C1/C2 Clutches. Clutch - Assemble - C1/C2 Clutches.

21.3 / 20 21.3 / 21

Clutch - Assemble - C1/C2 Clutches.

21.3 / 21

Clutch - Assemble - C1/C2 Clutches.

21.3 / 21

Clutch - Assemble - C1/C2 Clutches.

21.3 / 21

Clutch - Assemble - C1/C2 Clutches.

21.3 / 21

Clutch - Assemble - C1/C2 Clutches.

21.3 / 21

Clutch - Assemble - C1/C2 Clutches.

21.3 / 22

Clutch - Remove C3/C4 clutches

21.3 / 29

Clutch - Assemble - C3/C4 Clutches.

21.3 / 33

Clutch - Assemble - C3/C4 Clutches.

21.3 / 33

Clutch - Assemble - C3/C4 Clutches. Clutch - Assemble - C3/C4 Clutches.

21.3 / 33 21.3 / 33

Clutch - Assemble - C3/C4 Clutches.

21.3 / 33

Clutch - Assemble - C3/C4 Clutches. Clutch - Assemble - C3/C4 Clutches.

21.3 / 33 21.3 / 34

Clutch - Assemble - C3/C4 Clutches.

21.3 / 34

Clutch - Assemble - C3/C4 Clutches.

21.3 / 34

Clutch - Assemble - C3/C4 Clutches.

21.3 / 34

Clutch - Assemble - C3/C4 Clutches.

21.3 / 36

Transmission internal controls - Travel adjust

21.3 / 43

Powered front axle - Special tools

25.1 / 5

47538922 29/05/2013

Genuine 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000252 [Front Axle Ring Nut Wrench] 380000269 [Wheel Hub Bearing Ring Socket] 380000270 [Wheel Hub Bearing Pull Grips - Set Of Two] 380000265 [Swivel Housing Pin Pivot Puller] 380000234 [Swivel Pin Bearing Outer Race Puller] 380000235 [Swivel Housing Torque Check Adapter] 380200017 [Sunken Seal Key on Hub (without brakes)] 380200018 [Sunken seal Key on Spindle (with brakes)] 380200019 [Sunken Seal Key on Spindle for Axle Shafts] 380200041 [Differential Pinion Shaft Oil Seal Protection Shield Installer] 380200042 [Differential Pinion Shaft Oil Seal Installer] 380200041 [Differential Pinion Shaft Oil Seal Protection Shield Installer] 380200042 [Differential Pinion Shaft Oil Seal Installer] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000235 [Swivel Housing Torque Check Adapter] 380000235 [Swivel Housing Torque Check Adapter] 380000251 [Front Axle Overhaul Stand] 380000251 [Front Axle Overhaul Stand] 380000269 [Wheel Hub Bearing Ring Socket] 380200017 [Sunken Seal Key on Hub (without brakes)] 380200019 [Sunken Seal Key on Spindle for Axle Shafts] 380000269 [Wheel Hub Bearing Ring Socket] 380000269 [Wheel Hub Bearing Ring Socket] 380000251 [Front Axle Overhaul Stand] 380000251 [Front Axle Overhaul Stand] 380200018 [Sunken seal Key on Spindle (with brakes)]

Reference

PAGE

Powered front axle - Special tools

25.1 / 5

Powered front axle - Special tools

25.1 / 5

Powered front axle - Special tools

25.1 / 5

Powered front axle - Special tools

25.1 / 5

Powered front axle - Special tools

25.1 / 5

Powered front axle - Special tools

25.1 / 5

Powered front axle - Special tools

25.1 / 5

Powered front axle - Special tools

25.1 / 5

Powered front axle - Special tools

25.1 / 5

Powered front axle - Special tools

25.1 / 5

Powered front axle - Special tools

25.1 / 5

Powered front axle - Special tools

25.1 / 5

Four-Wheel Drive

25.1 / 16

Four-Wheel Drive

25.1 / 16

Bevel gear set and differential carrier - Adjust Ring/Pinion Gears

25.2 / 11

Bevel gear set and differential carrier - Adjust Ring/Pinion Gears

25.2 / 11

Steering knuckle and king pin - Adjust

25.3 / 5

Steering knuckle and king pin - Adjust

25.3 / 5

Planetary drive and hub - Disassemble

25.3 / 7

Planetary drive and hub - Disassemble

25.3 / 7

Planetary drive and hub - Disassemble

25.3 / 8

Planetary drive and hub - Assemble

25.3 / 9

Planetary drive and hub - Assemble

25.3 / 9

Planetary drive and hub - Assemble

25.3 / 9

Planetary drive and hub - Assemble

25.3 / 10

Planetary drive and hub - Disassemble

25.3 / 11

Planetary drive and hub - Disassemble

25.3 / 11

Wheel hub - Replace

25.3 / 14

47538922 29/05/2013

Genuine 380200018 [Sunken seal Key on Spindle (with brakes)] 380200018 [Sunken seal Key on Spindle (with brakes)] 380000569 [Tractor Separation Trolley] 380001116 [Transmission Lifting Eyebolts] 380000301 [Rotating Engine Stand] 380000569 [Tractor Separation Trolley] 380000249 [Universal Pinion Installation Tool Kit] 380001144 [Bevel Gear & Crownwheel Differential Lifting Hook] 380000237 [Rear Wheel Lifting Hook] 380000462 [Differential Overhaul Stand] 380000549 [Slide Hammer] 380000403 [Lifting Brackets (Set of Two)] 380001113 [Final Drive Housing Lifting Bracket] 380001114 [Crown Wheel Backlash and Differential Support Bearing Adjustment Tool] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 380000403 [Lifting Brackets (Set of Two)] 380000549 [Slide Hammer] 380000549 [Slide Hammer] 380001114 [Crown Wheel Backlash and Differential Support Bearing Adjustment Tool] 380001114 [Crown Wheel Backlash and Differential Support Bearing Adjustment Tool] 380001114 [Crown Wheel Backlash and Differential Support Bearing Adjustment Tool] 380000243 [Transmission Clutch Spring Compressor] 380000258 [Handgrip ] 50135 [Drift ] 380000243 [Transmission Clutch Spring Compressor] 380000243 [Transmission Clutch Spring Compressor] 380000243 [Transmission Clutch Spring Compressor]

Reference

PAGE

Wheel hub - Replace

25.3 / 14

Wheel hub - Replace

25.3 / 14

Powered rear axle - Special tools

27.1 / 4

Powered rear axle - Special tools

27.1 / 4

Powered rear axle - Special tools

27.1 / 4

Powered rear axle - Special tools

27.1 / 4

Powered rear axle - Special tools

27.1 / 4

Powered rear axle - Special tools

27.1 / 4

Powered rear axle - Special tools

27.1 / 4

Powered rear axle - Special tools

27.1 / 4

Powered rear axle - Special tools Powered rear axle - Special tools

27.1 / 4 27.1 / 4

Powered rear axle - Special tools

27.1 / 4

Powered rear axle - Special tools

27.1 / 4

Powered rear axle - Remove

27.1 / 14

Powered rear axle - Remove

27.1 / 16

Powered rear axle - Remove

27.1 / 16

Powered rear axle - Disassemble Powered rear axle - Disassemble Bevel gear - Adjust

27.1 / 18 27.1 / 20 27.2 / 13

Bevel gear - Adjust

27.2 / 13

Bevel gear - Adjust

27.2 / 14

Rear electro-hydraulic control - Special tools

31.1 / 4

Rear electro-hydraulic control - Special tools Rear electro-hydraulic control - Special tools Power Take-Off

31.1 / 4 31.1 / 4 31.2 / 16

Power Take-Off

31.2 / 16

Power Take-Off

31.2 / 17

47538922 29/05/2013

Genuine 380000982 [Parking Brake Disc Alignment Tool] 380000982 [Parking Brake Disc Alignment Tool] 380000982 [Parking Brake Disc Alignment Tool] 380000982 [Parking Brake Disc Alignment Tool] 380000543 [Hydraulic Test Quick Release Coupler (female) 1/4 NPTF] 291924 [Hydraulic Test Quick Release Coupler] 380000545 [Pressure Gauge Hose] 292246 [Pressure Gauge Hose] 380000550 [Trailer Brake Fitting] 380000552 [Pressure Gauge 0 - 40 Bar] 293242 [Pressure Gauge 0-40 Bar] 380000553 [Pressure Gauge 0-250 Bar] 293244 [Pressure Gauge 0-250 Bar] 380000550 [Trailer Brake Fitting] 380000553 [Pressure Gauge 0-250 Bar] 380000543 [Hydraulic Test Quick Release Coupler (female) 1/4 NPTF] 380000545 [Pressure Gauge Hose] 380000550 [Trailer Brake Fitting] 380000550 [Trailer Brake Fitting] 380000553 [Pressure Gauge 0-250 Bar] 380000543 [Hydraulic Test Quick Release Coupler (female) 1/4 NPTF] 380000545 [Pressure Gauge Hose] 380000550 [Trailer Brake Fitting] 380000550 [Trailer Brake Fitting] 380000552 [Pressure Gauge 0 - 40 Bar] 380000543 [Hydraulic Test Quick Release Coupler (female) 1/4 NPTF] 380000545 [Pressure Gauge Hose] 380000550 [Trailer Brake Fitting]

Reference

PAGE

Parking brake or parking lock - Special tools

33.2 / 3

Parking brake disks - Install

33.2 / 11

Parking brake disks - Install

33.2 / 11

Parking brake disks - Install

33.2 / 12

Trailer brake hydraulic control - Special tools

33.3 / 3

Trailer brake hydraulic control - Special tools

33.3 / 3

Trailer brake hydraulic control - Special tools

33.3 / 3

Trailer brake hydraulic control - Special tools

33.3 / 3

Trailer brake hydraulic control - Special tools

33.3 / 3

Trailer brake hydraulic control - Special tools

33.3 / 3

Trailer brake hydraulic control - Special tools

33.3 / 3

Trailer brake hydraulic control - Special tools

33.3 / 3

Trailer brake hydraulic control - Special tools

33.3 / 3

Trailer brake valve - Pressure test

33.3 / 21

Trailer brake valve - Pressure test

33.3 / 21

Trailer brake valve - Pressure test

33.3 / 21

Trailer brake valve - Pressure test

33.3 / 21

Trailer brake valve - Pressure test

33.3 / 21

Trailer brake valve - Pressure test

33.3 / 21

Trailer brake valve - Pressure test

33.3 / 21

Trailer brake valve - Pressure test

33.3 / 21

Trailer brake valve - Pressure test

33.3 / 21

Trailer brake valve - Pressure test

33.3 / 22

Trailer brake valve - Pressure test

33.3 / 22

Trailer brake valve - Pressure test

33.3 / 22

Trailer brake valve - Pressure test

33.3 / 22

Trailer brake valve - Pressure test

33.3 / 22

Trailer brake valve - Pressure test

33.3 / 22

47538922 29/05/2013

Genuine 380000550 [Trailer Brake Fitting] 380000552 [Pressure Gauge 0 - 40 Bar] 380000543 [Hydraulic Test Quick Release Coupler (female) 1/4 NPTF] 380000545 [Pressure Gauge Hose] 380000550 [Trailer Brake Fitting] 380000550 [Trailer Brake Fitting] 380000552 [Pressure Gauge 0 - 40 Bar] 380000543 [Hydraulic Test Quick Release Coupler (female) 1/4 NPTF] 380000545 [Pressure Gauge Hose] 380000550 [Trailer Brake Fitting] 297612 [Lifting Hooks]

Reference

PAGE

Trailer brake valve - Pressure test

33.3 / 22

Trailer brake valve - Pressure test

33.3 / 22

Trailer brake valve - Pressure test

33.3 / 22

Trailer brake valve - Pressure test

33.3 / 22

Trailer brake valve - Pressure test

33.3 / 23

Trailer brake valve - Pressure test

33.3 / 23

Trailer brake valve - Pressure test

33.3 / 23

Trailer brake valve - Pressure test

33.3 / 23

Trailer brake valve - Pressure test

33.3 / 23

Trailer brake valve - Pressure test

33.3 / 23

Remote control valve Closed center mechanical remote valve Special tools 380002720 [Load Check Valve Remote control valve Closed center mechanical remote valve Remover and Installer] Disassemble 380002720 [Load Check Valve Remote control valve Closed center mechanical remote valve Remover and Installer] Assemble Rear hitch housing - Remove 380000238 [Hydraulic Lift Housing Lifting Frame Adapter] Rear hitch housing - Remove 380000224 [Hydraulic Lift Lifting Hook] Rear hitch housing - Remove 380000238 [Hydraulic Lift Housing Lifting Frame Adapter] Rear hitch housing - Install 380000238 [Hydraulic Lift Housing Lifting Frame Adapter] Rear hitch housing - Install 380000224 [Hydraulic Lift Lifting Hook] 380000281 [Rotoglyd Steering Hydraulic control components - Special tools Seal Installer] 294056 [Rotoglyd Steering Hydraulic control components - Special tools Seal Installer] 380000492 [7/16 UNF Male Hydraulic control components - Special tools Quick Release Adapter] 297240 [7/16 UNF Male Quick Hydraulic control components - Special tools Release Adapter] 380000543 [Hydraulic Test Hydraulic control components - Special tools Quick Release Coupler (female) 1/4 NPTF] 291924 [Hydraulic Test Quick Hydraulic control components - Special tools Release Coupler] 380000545 [Pressure Gauge Hydraulic control components - Special tools Hose] 292246 [Pressure Gauge Hydraulic control components - Special tools Hose] 380000553 [Pressure Gauge Hydraulic control components - Special tools 0-250 Bar]

47538922 29/05/2013

35.4 / 3 35.4 / 13 35.4 / 19 37.1 / 9

37.1 / 9 37.1 / 9

37.1 / 10

37.1 / 10 41.3 / 3 41.3 / 3 41.3 / 3 41.3 / 3 41.3 / 3

41.3 / 3 41.3 / 3 41.3 / 3 41.3 / 3

Genuine 293244 [Pressure Gauge 0-250 Bar] 380000570 [Tee Adapter, 1/4 ORFS (Female) x 1/4 ORFS (Male) x 7/16 UNF (Female)] 297600 [Tee Adapter 11/16 ORFS Female X 11/16 ORFS Male X 7/16 UNF Female] 380000599 [Blanking Cap, 11/16 ORFS] 380000223 [Water Pump Puller used on 4.5L & 6.7L NEF Engines] 380000570 [Tee Adapter, 1/4 ORFS (Female) x 1/4 ORFS (Male) x 7/16 UNF (Female)] 380000492 [7/16 UNF Male Quick Release Adapter] 380000545 [Pressure Gauge Hose] 380000553 [Pressure Gauge 0-250 Bar] 380000621 [Quick Release Coupler (Female) x 1/4 NPTF] 380000281 [Rotoglyd Steering Seal Installer] 380000599 [Blanking Cap, 11/16 ORFS] 380000570 [Tee Adapter, 1/4 ORFS (Female) x 1/4 ORFS (Male) x 7/16 UNF (Female)] 380000492 [7/16 UNF Male Quick Release Adapter] 380000599 [Blanking Cap, 11/16 ORFS] 380000553 [Pressure Gauge 0-250 Bar] 380000621 [Quick Release Coupler (Female) x 1/4 NPTF] 380000545 [Pressure Gauge Hose] 380000281 [Rotoglyd Steering Seal Installer] 380001268 [Engine Belt Tension Meter ] 380000843 [Diagnostic Test Switch] 380000843 [Diagnostic Test Switch] 380000843 [Diagnostic Test Switch] 380000843 [Diagnostic Test Switch] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)]

Reference

PAGE

Hydraulic control components - Special tools

41.3 / 3

Hydraulic control components - Special tools

41.3 / 3

Hydraulic control components - Special tools

41.3 / 3

Hydraulic control components - Special tools

41.3 / 3

Power steering control valve - Remove

41.3 / 9

Power steering control valve - Pressure test for the power steering relief valve

41.3 / 12

Power steering control steering relief valve Power steering control steering relief valve Power steering control steering relief valve Power steering control steering relief valve Power steering control steering relief valve Power steering control steering relief valve Power steering control steering relief valve

valve - Pressure test for the power

41.3 / 12

valve - Pressure test for the power

41.3 / 12

valve - Pressure test for the power

41.3 / 12

valve - Pressure test for the power

41.3 / 12

valve - Pressure test for the power

41.3 / 12

valve - Pressure test for the power

41.3 / 12

valve - Pressure test for the power

41.3 / 12

Power steering control valve - Pressure test steering relief valve Power steering control valve - Pressure test steering relief valve Power steering control valve - Pressure test steering relief valve Power steering control valve - Pressure test steering relief valve Power steering control valve - Pressure test steering relief valve Power steering control valve - Assemble

for the power

41.3 / 12

for the power

41.3 / 12

for the power

41.3 / 12

for the power

41.3 / 12

for the power

41.3 / 12 41.3 / 17

Alternator - Special tools

55.4 / 3

Electronic module - View HH MENU ACCESS

55.6 / 11

Electronic module - H1 - Calibration procedures

55.6 / 43

Electronic module - H1 - Calibration procedures

55.6 / 49

Instrument cluster - Dynamic description setting hours worked

55.7 / 29

3010-Intake air pressure and temperature sensor - temperature signal too high 3010-Intake air pressure and temperature sensor - temperature signal too high 3010-Intake air pressure and temperature sensor - temperature signal too high 3010-Intake air pressure and temperature sensor - temperature signal too high

55.8 / 360

47538922 29/05/2013

55.8 / 360 55.8 / 361 55.8 / 362

Genuine 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380040185 [Harness Diagnostic /Repair Kit (NEF)] 380000315 [Recovery And Rrecharge Portable System (For Discharging And Recovering Of The Refrigerant)] 380000315 [Recovery And Rrecharge Portable System (For Discharging And Recovering Of The Refrigerant)]

Reference

PAGE

3011-Intake air pressure and temperature sensor - temperature signal too low 3011-Intake air pressure and temperature sensor - temperature signal too low 3011-Intake air pressure and temperature sensor - temperature signal too low 3011-Intake air pressure and temperature sensor - temperature signal too low 3016-Fuel temperature sensor - signal too low

55.8 / 370

3016-Fuel temperature sensor - signal too low

55.8 / 370

3016-Fuel temperature sensor - signal too low

55.8 / 371

3016-Fuel temperature sensor - signal too low

55.8 / 371

3019-Intake air pressure and temperature sensor - pressure signal too high 3019-Intake air pressure and temperature sensor - pressure signal too high 3019-Intake air pressure and temperature sensor - pressure signal too high 3037-Boost pressure sensor - signal low

55.8 / 373

3088-Crankshaft sensor - no signal

55.8 / 402

3088-Crankshaft sensor - no signal

55.8 / 402

3088-Crankshaft sensor - no signal

55.8 / 403

3088-Crankshaft sensor - no signal

55.8 / 403

3089-Crankshaft sensor - invalid signal

55.8 / 406

3089-Crankshaft sensor - invalid signal

55.8 / 406

3797-Differential pressure sensor - signal too high

55.8 / 659

55.8 / 364 55.8 / 364 55.8 / 365 55.8 / 366

55.8 / 373 55.8 / 374 55.8 / 381

Cab - Remove

90.1 / 4

Cab - Install

90.1 / 12

47538922 29/05/2013

CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47538922 29/05/2013 EN