New Holland T5.95 T5.105 T5.115 Tractor Service Manual (84568014) - PDF Download by www.heydownloads.com

SERVICE MANUAL

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

T5.95 T5.105 T5.115 Tractor

1/3 Part number 84568014

Part number 84568014 English March 2013

SERVICE MANUAL

T5.105 T5.115 T5.95

84568014 22/03/2013 EN

Link Product / Engine Product T5.105 T5.105 T5.105 T5.115 T5.115 T5.115 T5.95 T5.95 T5.95

Market Product Europe North America International Region North America International Region Europe Europe International Region North America

84568014 22/03/2013

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 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

Clutch ....................................................................................... 18 [18.112] Slip clutch or flywheel damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1

Transmission.............................................................................. 21 [21.118] Transmission/Rear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.104] Power shuttle transmission lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 [21.148] Transmission/Rear drive internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5 [21.154] Power shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6 [21.145] Gearbox internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.7 [21.160] Creeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.8 [21.168] Hi-Lo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.9

Four-Wheel Drive (4WD) system .................................................. 23 [23.202] Electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 [23.304] Four-Wheel Drive (4WD) gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2 [23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.3

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 84568014 22/03/2013

[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

Power Take-Off (PTO) ................................................................. 31 [31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.116] Three-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 [31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3

Brakes and controls .................................................................... 33 [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.204] Front axle brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3 [33.220] Trailer brake hydraulic control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.4

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.114] Three-point hitch control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

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

Steering..................................................................................... 41 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

Wheels ...................................................................................... 44 [44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1

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[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 [55.024] Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.523] Cab hitch controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.130] Rear three-point hitch electronic control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11

Platform, cab, bodywork, and decals ............................................. 90 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

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INTRODUCTION

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Contents INTRODUCTION Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Basic instructions for arc-welding on tractors with electronic lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Special tools NOTES FOR EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Part identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Advice IMPORTANT NOTICE All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND AGRICULTURE service technicians, in strict accordance with the instructions given and using any specific tools necessary. Anyone performing the operations described herein without strictly following the instructions is personally responsible for any eventual injury or damage to property.

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Safety rules SAFETY REGULATIONS TO PREVENT ACCIDENTS Most accidents or injuries that occur in workshops are the result of non--observance of simple and fundamental safety regulations. For this reason, IN MOST CASES THESE ACCIDENTS CAN BE AVOIDED: by foreseeing possible causes and consequently acting with the necessary caution and care. Accidents may occur with all types of vehicle, regardless of how well it was designed and built. A careful and judicious service technician is the best guarantee against accidents. Precise observance of the most basic safety rule is normally sufficient to avoid many serious accidents. DANGER: Never carry out any cleaning, lubrication or maintenance operations when the engine is running.

GENERAL • Carefully follow specified repair and maintenance procedures. • Do not wear rings, wristwatches, jewellery, unbuttoned or loose articles of clothing such as: ties, torn clothing, scarves, open jackets or shirts with open zips that may remain entangled in moving parts. It is advised to wear approved safety clothing, e.g: non--slip footwear, gloves, safety goggles, helmets, etc. • Do not carry out repair operations with someone sitting in the driver’s seat, unless the person is a trained technician who is assisting with the operation in question. • Operate the vehicle and use the implements exclusively from the driver’s seat. • Do not carry out operations on the vehicle with the engine running, unless specifically indicated. • Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc. • All repair and maintenance operations must be carried out using extreme care and attention. • Service steps and platforms used in a workshop or in the field should be built in compliance with the safety rules in force. • Disconnect the batteries and label all controls to indicate that the vehicle is being serviced. Block the machine and all equipment which should be raised. • Do not check or fill fuel tanks, accumulator batteries, nor use starting liquid when smoking or near naked flames, as these fluids are inflammable. • Brakes are inoperative if manually released for repair or maintenance purposes. In such cases, the machine should be kept constantly under control using blocks or similar devices. • The fuel nozzle should always be in contact with the filling aperture. Maintain this position until filling operations are completed in order to avoid possible sparks caused by the accumulation of static electricity. • Only use specified towing points for towing the tractor, connect parts carefully.Make sure that all pins and/or locks are secured in position before applying traction. Never remain near the towing bars, cables or chains that are operating under load • Transport vehicles that cannot be driven using a trailer or a low--loading platform trolley, if available. • When loading or unloading the vehicle from the trailer (or other means of transport), select a flat area capable of sustaining the trailer or truck wheels, firmly secure the tractor to the truck or trailer and lock the wheels in the position. • Electric heaters, battery--chargers and similar equipment must only be powered by auxiliary power supplies with efficient ground insulation to avoid electrical shock hazards. • Always use suitable hoisting or lifting devices when raising or moving heavy parts. • Take extra care if bystanders are present. • Never pour gasoline or diesel oil into open, wide and low containers. • Never use gasoline, diesel oil or other inflammable liquids as cleaning agents. Use non-flammable non-toxic proprietary solvents. • Wear safety goggles with side guards when cleaning parts with compressed air. • Limit the air pressure to a maximum of 2.1 bar (30.5 psi), according to local regulations. 84568014 22/03/2013

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• Do not run the engine in confined spaces without suitable ventilation. • Do not smoke, use naked flames, or cause sparks in the area when fuel filling or handling highly inflammable liquids. • Never use naked flames for lighting when working on the machine or checking for leaks. • All movements must be carried out carefully when working under, on or near the vehicle and wear protective equipment: helmets, goggles and special footwear. • When carrying out checks with the engine running, request the assistance of an operator in the driver’s seat. The operator must maintain visual contact with the service technician at all times. • If operating outside the workshop, position the vehicle on a flat surface and lock in position. If working on a slope, lock the vehicle in position and move to a flat area as soon as is safely possible. • Damaged or bent chains or cables are unreliable. Do not use them for lifting or towing. Always use suitable protective gloves when handling chains or cables. • Chains should always be safely secured. Ensure that fastening device is strong enough to hold the load foreseen. No persons should stop near the fastening point, trailing chains or cables. • Maintenance and repair operations must be carried out in a CLEAN and DRY area, eliminate any water or oil spillage immediately. • Do not create piles of oil or grease--soaked rags as they represent a serious fire hazard; store them in a closed metal container. Before starting the vehicle or implements, make sure that the driver’s seat is locked in position and always check that the area is free of persons or obstacles. • Empty pockets of all objects that may fall unobserved into the vehicle parts when disassembled. • In the presence of protruding metal parts, use protective goggles or goggles with side guards, helmets, special footwear and gloves. • Handle all parts carefully, do not put your hands or fingers between moving parts, wear suitable safety clothing -safety goggles, gloves and shoes.

WELDING OPERATIONS • When welding, use protective safety devices: tinted safety goggles, helmets, special overalls, gloves and footwear. All persons present in the area where welding is taking place must wear tinted goggles. NEVER LOOK AT THE WELDING ARC IF YOUR EYES ARE NOT SUITABLY PROTECTED. • Where possible, remove the part or tool that requires arc welding from the tractor. • Disconnect both battery leads. Isolate the cable ends to avoid contact with each other and the tractor. • Position the welder ground clamp as near as possible to the area where welding is taking place. • Remove the electronic control units located on the tractor if welding is to be carried out near these control units. • Never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding is in progress. • Metal cables tend to fray with repeated use. Always use suitable protective devices (gloves, goggles, etc.) when handling cables.

START UP • Never start the engine in confined spaces that are not equipped with adequate ventilation for exhaust gas extraction. • Never place the head, body, limbs, feet, hands or fingers near fans or rotating belts.

ENGINE • Always loosen the radiator cap slowly before removing it to allow any remaining pressure in the system to be discharged. Coolant should be topped up only when the engine is stopped or idle if hot. • Never fill up with fuel when the engine is running, especially if hot, in order to prevent the outbreak of fire as a result of fuel spillage • Never check or adjust fan belt tension when the engine is running. Never adjust the fuel injection pump when the vehicle is moving.

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• Never lubricate the vehicle when the engine is running.

ELECTRICAL SYSTEMS • If it is necessary to use auxiliary batteries, remember that both ends of the cables must be connected as follows: (+) with (+) and (-) with (-). • Avoid short-circuiting the terminals. GAS RELEASED FROM BATTERIES IS HIGHLY INFLAMMABLE. • During charging, leave the battery compartment uncovered to improve ventilation. • Never check the battery charge using ”jumpers” (metal objects placed on the terminals). • Avoid sparks or flames near the battery zone to prevent explosion hazards. • Before servicing operations, check for fuel or current leaks. Eliminate any eventual leaks before starting work. • Never charge batteries in confined spaces. Make sure that there is adequate ventilation in order to prevent accidental explosion hazards as a result of the accumulation of gases released during charging operations. • Always disconnect the battery before performing any kind of servicing on the electrical system.

HYDRAULIC SYSTEMS • Some fluid slowly coming out from a very small port can be almost invisible and be strong enough to penetrate the skin. Check for leaks using a piece of cardboard, NEVER USE HANDS. • If any liquid penetrates skin tissue, call for medical aid immediately • Serious skin infections may result if medical attention is not given. • Use the specific tools when checking pressure values on the hydraulic system.

WHEELS AND TYRES • Check that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodically check possible damages to the rims and tyres. • Stand away from (at the side of) the tire when checking inflation pressure. • Only check pressure when the vehicle is unloaded and the tires are cold, to avoid incorrect readings as a result of over--pressure. • Do not re--use parts of recovered wheels as incorrect welding or brazing may heat the material, causing it to weaken and eventually damage or break the wheel. • Never cut, nor weld a rim with the inflated tyre assembled. • When removing the wheels, lock both the front and rear vehicle wheels. • Always position support stands when raising the vehicle, in order to conform to current safety regulations. • Deflate the tyre before removing any object caught into the tyre tread. • Never inflate tires using inflammable gases; this could cause an explosion and put operator safety at risk.

REMOVAL AND RE-FITTING • Lift and handle all heavy parts using suitable lifting equipment and make sure that all slings and hooks are correctly secured. • Handle all parts carefully during lifting operations, keep an eye on the personnel working near the load to be lifted. Never insert hands or fingers between parts, always wear approved accident prevention clothing (goggles, gloves and work boots). • Avoid twisting chains or metal cables and always wear safety gloves when handling cables or chains.

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Basic instructions SHIMMING For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up the measured values: Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value indicated for each on shim.

ROTATING SHAFT SEALS For correct rotating shaft seal installation, proceed as follows: • thoroughly clean the shaft and check that the working surface on the shaft is not damaged; • position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that they will deviate the fluid towards the inner side of the seal; • coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip and the dust lip on double lip seals with grease; • insert the seal in its seat and press down using a seal installer; do not tap the seal with a hammer or mallet; • whilst inserting the seal, check that it is perpendicular to the seat; once settled. • to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.

O--RING SEALS Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twisting, which would jeopardise sealing efficiency.

SEALING COMPOUNDS Apply one of the following sealing compounds on the mating surfaces marked, on this manual, with an X: RTV 1473, RHODORSIL® CAF 1 or LOCTITE PLASTIC GASKET. Before applying the sealing compound, prepare the surfaces as follows: • remove any incrustations using a wire brush; •

WARNING Chemical hazard! Always wear protective clothing and goggles when cleaning with solvents, acids, or alkaline chemical agents. Always follow the chemical manufacturer's instructions. Failure to comply could result in death or serious injury. W0180A

thoroughly de-grease the surfaces using one of the following cleaning agents: trichlorethylene, Diesel fuel or a water and sodium hydroxide ( NaOH , also known as caustic soda) solution.

BEARINGS When installing bearings it is advised to: • heat the bearings to 80 ÷ 90 °C before fitting on the shafts; • allow the bearings to cool before installing them.

SPRING PINS When fitting split socket elastic pins, ensure that the pin notch is positioned in the direction of the force required to stress the pin. Spiral spring pins do not require special positioning.

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IMPORTANT NOTES Wear limit values indicated for certain parts are recommended, but not binding. The terms “front”, “rear”, ”right--hand” and ”left--hand” (when referred to different parts) are intended as seen from the driving position with the tractor in the normal direction of movement.

MOVING THE TRACTOR WITH THE BATTERY REMOVED External power supply cables should only be connected to the respective positive and negative cable terminals, using efficient clamps that guarantee adequate and secure contact. Disconnect all services (lights, windshield wipers, etc.) before starting the vehicle. If the vehicle electrical system requires checking, carry out operations with the power supply connected; Once checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.

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Basic instructions for arc-welding on tractors with electronic lift ATTENTION: Observe the following precautions when carrying out arc welding on a tractor fitted with an electronic lift. - Where possible, remove the part or implement that requires arc welding from the tractor. - Disconnect both battery leads. Isolate the cable ends to avoid contact with each other and the tractor. - Position the welder ground clamp as near as possible to the area where welding is to take place. - Remove the electronic control units located on the tractor if welding is to be carried out near these control units. - Never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding is in progress.

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Special tools NOTES FOR EQUIPMENT The tools that NEW HOLLAND AGRICULTURE propose and illustrate in this manual are: • specifically researched and designed for use with NEW HOLLAND AGRICULTURE vehicles; • necessary to make reliable repair; • accurately built and strictly tested to offer efficient and long--lasting working means. By using these tools, repair personnel will benefit from: • operating in optimal technical conditions; • obtaining the best results; • saving time and effort; • working in safe conditions.

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Consumables QUANTITY

Cooling system:

16 l (4.2 US gal)

Windscreen wash reservoir

2 l (0.5 US gal)

Fuel tank:

155 l (40.9 US gal)

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 bevel drive final drives and brakes gearbox hydraulic lift power take−off hydrostatic steering Front hubs

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

Grease fittings Air-conditioning refrigerant Air-conditioning compressor oil

RECOMMENDED NEW HOLLAND AGRICULTURE PRODUCTS Mixture of water and antifreeze NEW HOLLAND AMBRA AGRIFLU at 50 % + 50 % Water and Detergent liquid Decanted, filtered diesel fuel 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 G™ HYDRAULIC 63 l (16.6 US gal)

TRANSMISSION OIL

NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE

SPECIFICATION NEW HOLLAND AGRICULTURE

INTERNATIONAL SPECIFICATION

NH 900 A

MAT3521

API CJ-4 ACEA E7/E9

NH 610 A

ISO 7308

NH 410 B

API GL4 ISO 32/46 SAE 10W-30

NH 710 A

NLGI 2

GREASE

650 g (22.9 oz)

R134A

0.185 l (0.05 US gal)

SP10

84568014 22/03/2013

INTRODUCTION

Part identification Use solely genuine parts, which guarantee the same quality, duration and safety as the original parts as they are identical to the ones fitted during production. Only genuine parts can offer this guarantee. When ordering spare parts, always provide the following information: • tractor model (commercial name) and frame number; • engine type and number; • part number of the ordered part, which can be found in the “Microfiches” or the “Spare Parts Catalogue”, used for order processing.

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SERVICE MANUAL Engine

T5.105 T5.115 T5.95

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Contents Engine - 10

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

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 T5.105 , T5.115 , T5.95

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

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Engine - 10 Engine and crankcase - 001

T5.105 T5.115 T5.95

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Contents Engine - 10 Engine and crankcase - 001

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

SERVICE Engine Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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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) 84568014 22/03/2013

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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 - 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) at its terminal (2) has a decoupler, that reacts, when the temperature changes, only lengthwise.

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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) and the pipe delivering oil to the spool valve (3). Remove the fasteners 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 tool for dismantling tractors 380000569 (2) with the bracket and adapter plate under the engine and place a wooden block (1) in between the points of contact between the tool 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

Engine - Engine and crankcase

Engine - Install 1.

- Refit the flexible belt on the alternator and take up the slack according to the procedure in Accessory belt - 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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Index Engine - 10 Engine and crankcase - 001 Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - 10 Fan and drive - 414

T5.105 T5.115 T5.95

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Contents Engine - 10 Fan and drive - 414

SERVICE Accessory belt Tension adjust belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.

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Engine - Fan and drive

Accessory belt - Tension adjust belt T5.

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 Accessory belt - Tension adjust belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.

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

T5.105 T5.115 T5.95

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

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

Diesel Particulate Filters (DPF) - 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 84568014 22/03/2013

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

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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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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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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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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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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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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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) - Dynamic description manual regeneration of the diesel particulate filter (DPF) 6 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

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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.

84568014 22/03/2013 EN

SERVICE MANUAL Clutch

T5.105 T5.115 T5.95

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Contents Clutch - 18

[18.112] Slip clutch or flywheel damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1 T5.105 , T5.115 , T5.95

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Clutch - 18 Slip clutch or flywheel damper - 112

T5.105 T5.115 T5.95

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Contents Clutch - 18 Slip clutch or flywheel damper - 112

FUNCTIONAL DATA Viscous or flexible coupling Sectional view Longitudinal section through flexible coupling. Power Shuttle unit . . . . . . . . . . . . . . . . . . . 3

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Clutch - Slip clutch or flywheel damper

Viscous or flexible coupling - Sectional view Longitudinal section through flexible coupling. Power Shuttle unit

SEZ18CAP1B-3

1. Flywheel. 2. Flexible coupling. 3. Shuttle clutch driving shaft. 4. Engine / flywheel retaining bolts.

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Index Clutch - 18 Slip clutch or flywheel damper - 112 Viscous or flexible coupling - Sectional view Longitudinal section through flexible coupling. Power Shuttle unit . 3

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

84568014 22/03/2013 EN

SERVICE MANUAL Transmission

T5.105 T5.115 T5.95

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Contents Transmission - 21

[21.118] Transmission/Rear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 T5.105 , T5.115 , T5.95

[21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 T5.105 , T5.115 , T5.95

[21.104] Power shuttle transmission lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 T5.105 , T5.115 , T5.95

[21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 T5.105 , T5.115 , T5.95

[21.148] Transmission/Rear drive internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5 T5.105 , T5.115 , T5.95

[21.154] Power shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6 T5.105 , T5.115 , T5.95

[21.145] Gearbox internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.7 T5.105 , T5.115 , T5.95

[21.160] Creeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.8 T5.105 , T5.115 , T5.95

[21.168] Hi-Lo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.9 T5.105 , T5.115 , T5.95

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Transmission - 21 Transmission/Rear drive - 118

T5.105 T5.115 T5.95

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Contents Transmission - 21 Transmission/Rear drive - 118

FUNCTIONAL DATA Transmission drive housing Exploded view Sealing compound application diagram for transmission--gear box casing . . . . . . . . . . . . 3

SERVICE Transmission drive housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Transmission - Transmission/Rear drive

Transmission drive housing - Exploded view Sealing compound application diagram for transmission--gear box casing

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Transmission - Transmission/Rear drive

SEZ27CAP1H-5

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Transmission - Transmission/Rear drive

Transmission drive housing - Remove To remove the rear transmission-gearbox casing proceed as follows: 1.

Detach the cab (1) as described in the operation (see. Cab and platform - Remove (90.150) and rest it on a wooden support base.

WLAPL4S90C131A

WLAPL4S10C117A

MOIL12APL0053AA

MOIL12APL0054AA

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

Remove the fourâ&#x2C6;&#x2019;wheel drive transmission shaft guard by unscrewing the front, central and rear retaining bolts. Take off the circlip (2) and extract the sleeve (1) from the front axle pinion.

Take off the circlip (2) and extract the sleeve from the drive.

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Transmission - Transmission/Rear drive

Remove the drive shaft central support retaining bolts (1) and extract the shaft together with the support.

MOIL12APL0055AA

MOIL12APL0003AA

MOIL12APL0077AA

MOIL12APL0056AA

Remove the front support of the fuel tank (1) and the relevant fasteners (2). Afterwards take out the screws (3) fixing the rear support (4) and remove the support itself.

Detach the pump oil suction pipe (2) from the gearbox--transmission casing, loosen the union and detach the delivery pipe (1) from the pump to the trailer brake spool valve / lift / spool valves.

Disconnect the trailer brake control piping (1) from the supporting plate (2).

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Transmission - Transmission/Rear drive

Disconnect the electrical connection (1) on the PTO rev counter.

MOIL12APL0057AA

10.

11.

12.

Detach the lock pin (1) and the support pin (2) , then remove the top link (3).

MOIL12APL0058AA

MOIL12APL0059AA

MOIL12APL0060AA

Detach the two pipes (1) from the trailer brake valve (where applicable) to the rear brakes, the electric connector (2) to the two solenoids of the lift control valve, the load sensing piloting valve (3) and the oil recovery pipes (4) from the quick couplers.

Detach the spool piloting (1) and diverter outlet (2) pipes. Detach the feed pipe from the pump to the spool valve assembly (3) and the one to the ventral spool valves (4) (where applicable). If present, disconnect the connection pipe from the trailer brake valve to the Italian spool valve (5) and the electrical connector connected to the pressure sensor on the trailer brake valve.

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Transmission - Transmission/Rear drive

13.

14.

15.

16.

Using a suitable hoist, support the auxiliary spool valves unit, take out the retaining bolts (1) and extract the unit from the tractor. Set the unit on a workbench.

MOIL12APL0061AA

MOIL12APL0062AA

MOIL12APL0063AA

MOIL12APL0064AA

Where applicable, remove the trailer brake valve control spool valve (1).

Take out the screws (2) , detach the connections to the sensors (1) , lift and take off the cover (3), transmission-gearbox casing assembly.

Remove the union (1) and disconnect the power take--off brake control pipe (2).

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Transmission - Transmission/Rear drive

17.

Disconnect the pipe (2) delivering oil to the cylinder, detach the lift cylinder support bracket (1), then extract the cylinder (3). Repeat this operation on the other side too.

18.

Detach the pipe delivering oil to the lift cylinders (1). Unscrew the fixing screws (2). Hook the box (3) onto a hoist with a lifting hook and remove the hydraulic lift.

19.

Remove the union (1) and disconnect the p.t.o. coupling control pipe (2). Remove the union (3) and disconnect the power take--off lubrication pipe (4). On the left-hand side, remove the power takeâ&#x2C6;&#x2019;off brake coupling pipe and fitting.

20.

21.

MOIL12APL0065AA

MOIL12APL0067AA

MOIL12APL0025AA

MOIL12APL0067AA

Remove the eccentric nut (1) for adjusting the travel of the spool valve stem (2), remove the fork on the valve and detach the lever. Remove the fourâ&#x2C6;&#x2019;wheel drive disengagement pipe.

Position one mobile stand (1) of tool 380000569 under the front part of the transmission--gearbox casing and the other mobile stand under the rear part of the casing.

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Transmission - Transmission/Rear drive

22.

23.

24.

25.

Position the fixed stand (1) of the tool 380000569 under the clutch casing (2) and put a block of wood (3) in between. Set two fixed stands under the final drives.

MOIL12APL0069AA

MOIL12APL0027AA

MOIL12APL0070AA

MOIL12APL0071AA

Detach the remaining lines on the services spool valve. Detach the electric connectors of the solenoids on the valve (1) , detach the hydraulic connection (2) with the fourâ&#x2C6;&#x2019;wheel drive casing, take out the nuts (3) fixing the spool valve to the transmission-gearbox casing, then, using suitable lifting equipment, remove the valve.

Using a chain, hitch the towing hook to the hoist, unscrew the six retaining bolts (1) and detach the towing hook (2).

Unscrew the nut (1), extract the bolt, remove the lower arms (3) and relative spacers (2).

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Transmission - Transmission/Rear drive

26.

27.

28.

29.

Take out the screw (1) and remove the oil recovery tank.

MOIL12APL0072AA

MOIL12APL0073AA

MOIL12APL0075AA

MOIL12APL0076AA

Using a chain, connect the power takeâ&#x2C6;&#x2019;off unit (1) to the hoist, unscrew the retaining bolts and detach the unit from the transmission--gearbox casing (2).

Using a chain, connect the right--hand final drive unit (1), unscrew the nuts and detach the unit from the transmission--gearbox casing, removing the ring gear (2) with the brake unit (3) and the friction plate (4).

Fasten the chain (1) to the transmission-gearbox casing (2), connect it to the hoist and take up the strain. Take out the fixing screws and detach the transmission-gearbox casing from the clutch housing using the stand 380000569.

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Transmission - Transmission/Rear drive

Transmission drive housing - Install To refit the rear transmission-gearbox casing, proceed as follows: 1.

For the correct orientation of the various parts, refer to the illustrations (see. Transmission/Rear drive internal components - Sectional view (21.148) , Transmission internal controls - Sectional view gear and range engagement devices (21.148) , Planetary final drive - Sectional view rear transmission transverse sections (27.120)).

Before refitting the casings, supports and covers, clean and de--grease the mating surfaces and apply a bead of sealing compound of approximately 2 mm (0.0787 in) in diameter, as shown (see. Rear axle housing - Exploded view Sealing compound application diagram for transmission--gear box casing (27.100)).

Respect the tightening torques (see. Powered rear axle - Torque (27.100)).

Using stand 380000569, refit the rear transmission-gearbox casing to the clutch casing.

Fit the flex bar and internal drive rod.

Position the left-hand brake friction disk and secure with the differential lock control fitting. Assemble the brake unit, ring gear and final drive unit.

Assemble the right-hand brake friction disk, the brake unit, ring gear and final drive unit.

Refit the power take−off unit to the gearbox-transmission casing.

Assemble the lift internal tank with relative oil drainage pipe.

10.

Assemble the lower arms and relative spacers.

11.

Assemble the towing hook.

12.

Assemble the services spool valve, connect all the piping between the valves and the various services.

13.

Connect the solenoid valve override lever with synchronised power take−off with gearbox engaged, adjusting the power take−off gearbox flexible cable (see. Power Take-Off (PTO) speed rate selector - Adjust PTO gearbox flexible stay. (31.104), Synchronized Power Take-Off (PTO) controls - Adjust synchronized PTO cable flexible stay. (31.104), Remote control valve - Install (35.204)).

14.

Set fixed stands under the final drive casings and remove the stand 380000569.

15.

Connect the electrical connections to the relative solenoid valves and gauges.

16.

Connect the PTO control and lubrication lines and relative brake.

17.

Refit the hydraulic lift and connect the relevant piping to the lift cylinders.

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Transmission - Transmission/Rear drive

18.

Reinstall the transmission-gearbox cover, fit on the fasteners and the various sensors housed on it.

19.

Fit on the Italian trailer brake valve control spool valve, where applicable.

20.

Set the spool valve pack back on the machine and secure it to the lift cover. Connect the pipes to the trailer brake, to the diverter, the oil delivery and return to the spool valve, the oil recovery from the quick couplers and the electrical connections to the electronic lift control valve.

21.

Mount the top link and the relevant support pin.

22.

Connect the power take-off speed sensor connection.

23.

Connect the trailer brake connection piping on the relevant support bracket.

24.

Connect the oil delivery and drain pipes from the pump to the spool valves/trailer brake/lift.

25.

Fit the fuel tank supports.

26.

Assemble the drive shaft, securing with the central support and the front and rear sleeves.

27.

Position and secure the drive shaft guard.

28.

Screw the oil drain plug onto the gearbox-rear transmission casing and fill it with oil observing the stated quantities (see. Consumables ()).

29.

Refit the cab, positioning it on the transmission as directed in the operation (see. Cab and platform Install (90.150)).

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Transmission - Transmission/Rear drive

Transmission drive housing - Assemble NOTE: For the correct orientation of the various parts, refer to the illustrations on ( Transmission/Rear drive internal components - Sectional view (21.148), Planetary final drive - Sectional view rear transmission transverse sections (27.120). 1.

Respect the tightening torques listed in Powered rear axle - Torque (27.100) .

Position the casing vertically, insert the gearbox driven shaft gear assembly (2) and fit the shaft (1).

SEZ27CAP1B-3

SEZ27CAP1A-76

Rotate the casing through 90 Â° (90 Â°), assemble the front bearing (1) and nut (2), tightening to the prescribed torque value.

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Transmission - Transmission/Rear drive

Fit the bearing (2) in its seat on the casing (front side) and lock it with the plate (1).

Insert the gear forks ( (1) and (3)) on the synchronizer sliding rings ( (2) and (4)).

Assemble the bevel pinion with all parts and carry out the adjustments described (see from Bevel gear - Adjust Tapered roller bearings adjustment for pinion shaft (27.106)).

SEZ27CAP1A-77

SEZ27CAP1A-78

SEZ27CAP1A-79

SEZ27CAP1A-80

Assemble the gearbox driving shaft, with all parts, and the adjusting shim (see adjustment in Transmission shaft - Adjust (21.140)), then position the bearing (2) and secure with the circlip (1).

Insert the final drive driving shaft, from the rear, fit the bearing (2) in the seat and secure with the circlip (1).

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Transmission - Transmission/Rear drive

Fit the lever (1) governing the p.t.o. synchronized with the gearbox comprehensive of spring, pawl and external lever.

10.

Fit the bevel crown wheel assembly (see adjustments in Bevel gear - Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. (27.106)).

11.

Assemble the differential lock engagement fork and spring rod, external plate and relative adjusting shims (see Differential lock hydraulic control Adjust (27.106)).

12.

Assemble the piston and differential lock control union.

13.

Assemble all the gearbox and range control rods, forks and teeth.

14.

Assemble the drive unit.

SEZ27CAP1A-81

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Transmission - Transmission/Rear drive

Transmission drive housing - Disassemble Gearbox transmission casing and adjustments 1.

Fix the gearbox--transmission casing to the rotating stand 380000301 using front bracket and rear bracket .

SEZ27CAP1A-54

SEZ27CAP1A-55

SEZ27CAP1A-56

SEZ27CAP1A-57

Rotate the casing through 180 Â° unscrew the bolts (1) and remove the drive casing (2).

Rotate the casing through 180 Â° using a punch, extract the pins (1) and remove the rods, teeth and control forks on the gear and range unit.

Extract the oil inlet union (1), tighten one bolt and extract the differential lock control piston.

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Transmission - Transmission/Rear drive

Unscrew the bolts (1), detach the stop plate (2) and remove the adjusting shims.

SEZ27CAP1A-58

SEZ27CAP1A-59

SEZ27CAP1A-60

SEZ27CAP1A-61

Using a punch, remove the pin (2) securing the differential lock engagement fork (1), extract the rod (4) and remove the spring (3) and fork.

Unscrew the bolts (1) securing the differential support (carry out on both sides).

Remove the differential bearing supports (1) from the seat (on both sides) and remove the bevel crown wheel, complete with differential, from the transmission casing.

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Transmission - Transmission/Rear drive

Extract the pin (2) and detach the external lever (1) for the PTO synchronized with gearbox.

SEZ27CAP1A-62

10.

11.

12.

Extract the internal lever (2), spring (1) and block (3).

SEZ27CAP1A-63

SEZ27CAP1A-64

SEZ27CAP1A-65

Release and unscrew the nut (1) securing the driven shaft.

Remove the circlip (1) retaining the final drive driving shaft bearing from the rear.

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Transmission - Transmission/Rear drive

13.

14.

15.

16.

Using a hammer and a brass punch (1) extract the mid gear unit (2) together with the relative bearing and engagement sleeve (3).

SEZ27CAP1A-66

SEZ27CAP1A-67

SEZ27CAP1A-68

SEZ27CAP1A-69

Extract the final drive driving shaft (1).

Remove the circlip (1) retaining the bearing (2) on the gearbox driving shaft.

Fit the tool 50006 (2) on the driving shaft and, using the extractor (1), remove the driving shaft, retrieving the bearings, gears and bushings.

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Transmission - Transmission/Rear drive

17.

18.

19.

20.

Release the washer on the nut (1) and loosen the nut.

SEZ27CAP1A-70

SEZ27CAP1A-71

SEZ27CAP1A-72

SEZ27CAP1A-73

Tighten the adapter 50144 (2) on the pinion (3) and, using the extractor (1), move the bevel pinion, in the direction indicated, by a few millimeters.

Move the engagement sleeve (1) until pliers (2) can be inserted to remove the circlip.

Move the gear unit (1) in the direction indicated by the arrow and remove the two split rings (2), unscrew the nut (3) and extract the bevel pinion and all parts.

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Transmission - Transmission/Rear drive

21.

22.

Unscrew the bolts (3), disassemble the support plate (1) and remove the bearing (2).

SEZ27CAP1A-74

SEZ27CAP1A-75

Using a brass punch (2) and hammer, extract the driven shaft (1) and remove all parts.

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Index Transmission - 21 Transmission/Rear drive - 118 Transmission drive housing - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Transmission drive housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Transmission drive housing - Exploded view Sealing compound application diagram for transmission--gear box casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Transmission drive housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Transmission drive housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Transmission - 21 Power shuttle transmission - 112

T5.105 T5.115 T5.95

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Contents Transmission - 21 Power shuttle transmission - 112

TECHNICAL DATA Power shuttle transmission General specification TRANSMISSION MAIN DATA (12 x 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

General specification POWER SHUTTLE UNIT MAIN DATA (12 x 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Torque power shuttle (12 x 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

General specification TRANSMISSION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

General specification POWER SHUTTLE UNIT MAIN DATA (24 x 24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Torque POWER SHUTTLE AND DUAL COMMAND (2 SPEED POWER SHIFT) . . . . . . . . . . . . . . . . . . . 9 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

General specification POWER SHUTTLE TRANSMISSION WITH CREEPER UNIT - 20X20 VERSION 13 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Torque Power Shuttle transmission with creeper unit - 20X20 version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

FUNCTIONAL DATA Power shuttle transmission Mechanical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Sectional view Longitudinal cross-sectional view of Power Shuttle gearbox. . . . . . . . . . . . . . . . . . . . . . . . 22 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Hydraulic schema Power Shuttle transmission -- Main hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Sectional view Longitudinal cross--sectional view of Power Shuttle with Dual Command (2 Speed Power Shift) function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Sectional view Cross--sectional view of Power Shuttle with Dual Command (2 Speed Power Shift) function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

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Hydraulic schema with (2 Speed Power Shift) (24+24), 30 km/h (18.64 mph) version (Neutral). . . . . . . 30 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Hydraulic schema with Dual Command (2 Speed Power Shift) (24+24) - Lubrication circuit. . . . . . . . . . 32 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Hydraulic schema with Dual Command (2 Speed Power Shift) (24+24) - Clutch A in discharge . . . . . . 35 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Hydraulic schema with Dual Command (2 Speed Power Shift) (24+24) - Clutch A under pressure. . . . 38 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Hydraulic schema with Dual Command (2 Speed Power Shift) function (24+24) - Clutch C under pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Hydraulic schema with Dual Command (2 Speed Power Shift) function (24+24) - Clutch C in discharge 44 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Mechanical schema Power Shuttle transmission with Dual Command (2 Speed Power Shift) . . . . . . . . 47 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Static description power shuttle and dual command (2 speed power shift) - Speed Transmission. . . . . 50 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Static description power shuttle and dual command (2 speed power shift) - Power Shuttle unit. . . . . . . 51 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Exploded view applying sealing compound. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Mechanical schema of the Power Shuttle transmission with creeper unit - 20X20 version . . . . . . . . . . . 54 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Sectional view longitudinal Power Shuttle and creeper unit gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Static description Power Shuttle transmission with creeper unit -- 20X20 version . . . . . . . . . . . . . . . . . . 59 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

SERVICE Transmission housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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Transmission - Power shuttle transmission

Power shuttle transmission - General specification TRANSMISSION MAIN DATA (12 x 12) T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

4 speed, constant--mesh, with synchronizers on all gears helical toothed ordinary gear train with 3 ranges providing a total of 12 gears spur independent, by two hand levers located at the operator’s right side

Gears Gearing type Reduction unit Gearing type Gearbox and reduction unit controls

Power shuttle transmission - General specification POWER SHUTTLE UNIT MAIN DATA (12 x 12) T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Hydraulic control valve

Power Shuttle gearbox and services working pressure Power Shuttle transmission lubrication pressure Power Shuttle unit Driving Number of driven plates in each clutch Driven disc thickness Driven plate material Number of driving plates in each clutch Drive disc thickness Driving plate material Thickness of clutch assembly under a load of 1600 N (359.69 lb)

mounted on the outer left-hand side of the clutch casing, comprising: -- no. 2 proportional solenoid valves controlling clutches A and B; -- no. 1 discharge solenoid valve -- 1 pressure regulating valve; -- no. 2 unions for checking the pressure of the various clutches. – 1 Pressure switch calibrated to 10 bar (145.00 psi) for the oil pressure control fitted between the pressure regulating valve and the discharge solenoid valve 18 bar (261.00 psi) (18,35 Kg/cm²) 2.9 - 3.7 bar (42.05 - 53.65 psi) to reverse without having to stop the tractor or use the clutch pedal. by means of hand lever located under the steering wheel, to the left-hand side of the operator. 5 2.65 - 2.75 mm (0.104 - 0.108 in) N 401–2 5 2.15 - 2.25 mm (0.085 - 0.089 in) or 2.35 - 2.45 mm (0.093 - 0.097 in) steel 25.3 - 25.5 mm (1.000 - 1.004 in) (*)

(*): Value to obtain by varying the thickness of the driving plates.

Power shuttle transmission - Torque power shuttle (12 x 12) T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

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Transmission - Power shuttle transmission

WLAPL4S21C302F

PARTS TO BE TIGHTENED Driven shaft manifold cover retaining nut (C1). Lubrication manifold retaining screw (C2) Clutch A bell housing retaining nut (C3) Flexible coupling retaining nut (C4) (*) Spacer retaining screw (C5) (*): Apply 1 or 2 drops of LOCTITE® 270 before tightening.

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Tightening torque kgm Nm (lbft) 22 - 25 N·m (16.23 2,24 ÷ 2,55 18.44 lb ft) 22 - 25 N·m (16.23 2,24 ÷ 2,55 18.44 lb ft) 22 - 25 N·m (16.23 2,24 ÷ 2,55 18.44 lb ft) 30 - 34 N·m (22.13 3,06 ÷ 3,46 25.08 lb ft) 87 105 - 115 N·m (77.44 10,7 ÷ 11,7 84.82 lb ft)

Transmission - Power shuttle transmission

WLAPL4S21C303F

PARTS TO BE TIGHTENED Control valve cap (C1) Clutch pressure control union (C2) Oil delivery union (C3) Oil delivery T union (C4)

Tightening torque kgm Nm (lbft) 70 - 90 N·m (51.63 7,1 ÷ 9,2 66.38 lb ft) 22 - 29 N·m (16.23 2,24 ÷ 3 21.39 lb ft) 70 - 90 N·m (51.63 7,1 ÷ 9,2 66.38 lb ft) 48 - 66 N·m (35.40 4,9 ÷ 6,7 48.68 lb ft)

Power shuttle transmission - Special tools T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

• 380000301: Rotating stand for overhaul operations. • 380000291: Tool for A and B clutch springs. • 380000290: Tool for fitting internal hub seals on A and B clutches. • 380000296: Tool for fitting clutch driving shaft seal (with 380000258). • 380000289: Limp home device. • 380000843: Connector to access HH diagnostic programs.

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Transmission - Power shuttle transmission

TOOLS TO BE MADE IN THE WORKSHOP • 50169: Tool to be made to remove-install the clutch-gearbox casing on the engine (mark the tool with the no. 50169 − Measurements in mm) Make of UNI C40

50169

• 50223: Guide pins to be made to remove-install the cover of clutch A (mark the tool with the no. 50223 − Measurements in mm) Make of UNI C40

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Transmission - Power shuttle transmission

50223

Power shuttle transmission - General specification TRANSMISSION DATA T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Gears Gearing type Reduction unit Gearing type Gearbox and reduction unit controls

Power shuttle transmission - General specification POWER SHUTTLE UNIT MAIN DATA (24 x 24) T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Hydraulic control valve

Power Shuttle gears and services working pressure Battery

mounted on the outer left-hand side of the clutch casing, comprising: - no. 4 control solenoid valves; - no. 1 pressure regulating valve; - no. 1 accumulator; - no. 4 unions for checking the pressure of the various clutches. - 1 Pressure switch calibrated to 10 bar (145.00 psi) for the oil pressure control fitted on the solenoid valve feed pressure line. 18 bar (261.00 psi) (18,35 Km/cmÂ˛) with diaphragm

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Transmission - Power shuttle transmission

Power Shuttle transmission lubrication pressure Power Shuttle unit Method of operation Number of driven plates in each clutch Driven disc thickness Driven plate material Number of driving plates in each clutch Drive disc thickness Driving plate material Thickness of clutch assembly under a load of 1600 N (359.69 lb)

2.9 - 3.7 bar (42.05 - 53.65 psi) to reverse without having to stop the tractor or use the clutch pedal. by means of hand lever located under the steering wheel, to the left-hand side of the operator. 5 2.65 - 2.75 mm (0.10 - 0.11 in) N 401-2 5 2.15 - 2.25 mm (0.085 - 0.089 in) or 2.35 - 2.45 mm (0.093 - 0.096 in) steel 25.3 - 25.5 mm (0.996 - 1.004 in) (*)

(*): Value to obtain by varying the thickness of the driving plates.

Power shuttle transmission - Torque POWER SHUTTLE AND DUAL COMMAND (2 SPEED POWER SHIFT) T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

WLAPL4S21C401F

PARTS TO BE TIGHTENED Clutch A cover retaining screw ( (C1), 2) Lubrication manifold retaining screw (C2) Driven shaft manifold cover retaining nut (C3)

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Tightening torque kgm Nm (lbft) 22 - 25 N·m (16.23 2,24 ÷ 2,55 - 18.44 lb ft) 22 - 25 N·m (16.23 2,24 ÷ 2,55 - 18.44 lb ft) 22 - 25 N·m (16.23 2,24 ÷ 2,55 - 18.44 lb ft)

Transmission - Power shuttle transmission

PARTS TO BE TIGHTENED Flexible coupling retaining nut (C4) (*) Control valve cap (C1), 2) Control valve retaining screw (C2) Control valve retaining screw (C3) Accumulator union (C4) Accumulator (C5) Solenoid valve pin retaining screw (C6) Solenoid valve retaining nut (C7) (•) Clutch pressure control union (C8) Oil T fitting (C9) Oil fitting (C10) (•): Apply 1 or 2 drops of LOCTITE® 542 before tightening. (*): Apply 1 or 2 drops of LOCTITE® 270 before tightening.

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Tightening torque kgm Nm (lbft) 30 - 34 N·m (22.13 3,04 ÷ 3,45 - 25.08 lb ft) 70 - 90 N·m (51.63 7,1 ÷ 9,2 - 66.38 lb ft) 51 - 62 N·m (37.62 5,2 ÷ 6,3 - 45.73 lb ft) 136 - 165 N·m (100.31 - 121.70 lb 13,9 ÷ 16,8 ft) 70 - 90 N·m (51.63 7,1 ÷ 9,2 - 66.38 lb ft) 70 - 90 N·m (51.63 7,1 ÷ 9,2 - 66.38 lb ft) 15 - 21 N·m (11.06 1,53 ÷ 2,14 - 15.49 lb ft) 2 - 3 N·m (1.48 0,2 ÷ 0,3 2.21 lb ft) 22 - 29 N·m (16.23 2,24 ÷ 3 - 21.39 lb ft) 48 - 66 N·m (35.40 4,9 ÷ 6,7 - 48.68 lb ft) 8 to 66 70 - 90 N·m (51.63 7,1 ÷ 9,2 - 66.38 lb ft)

Transmission - Power shuttle transmission

SEZ21CAP4G-7

Power shuttle transmission - Special tools T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

POWER SHUTTLE AND DUAL COMMAND (2 SPEED POWER SHIFT) • 380000301: Rotating stand for overhaul operations. • 380000291: Tool for A and B clutch springs. • 380000290: Tool for fitting internal hub seals on A and B clutches. • 380000296: Tool for fitting clutch driving shaft seal (with 380000258). • 380000243: Press for Dual Command (2 Speed Power Shift) hydraulic clutch springs. • 380000244: Dual Command (2 Speed Power Shift) hydraulic clutch shaft stop and support. • 380000245: Tool for fitting seals on Dual Command (2 Speed Power Shift) hydraulic clutch hub. • 380000289: Limp home device. 84568014 22/03/2013

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Transmission - Power shuttle transmission

TOOLS TO BE MADE IN THE WORKSHOP • 50169: Tool to be made to remove-install the clutch-gearbox casing on the engine (mark the tool with the no. 50169 − Measurements in mm) Make of UNI C40

50169

• 50223: Guide pins to be made to remove-install the cover of clutch A (mark the tool with the no. 50223 − Measurements in mm) Make of UNI C40

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Transmission - Power shuttle transmission

50223

Power shuttle transmission - General specification POWER SHUTTLE TRANSMISSION WITH CREEPER UNIT - 20X20 VERSION T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

TRANSMISSION DATA 4 speed, constant--mesh, with synchronizers on all gears helical toothed ordinary gear train with 3 ranges providing a total of 12 gears spur independent, by two hand levers located at the operatorâ&#x20AC;&#x2122;s right side

Transmission Gearing type Reduction unit Gearing type Gearbox and reduction unit controls

POWER SHUTTLE UNIT DATA

Hydraulic control valve

Power Shuttle gearbox and services working pressure Power Shuttle transmission lubrication pressure

mounted on the outer left-hand side of the clutch casing, comprising: - no. 2 proportional solenoid valves controlling clutches A and B; no. 1 discharge solenoid valve - one pressure regulating valve; - no. 2 unions for checking the pressure of the various clutches. - 1 Pressure switch calibrated to 10 bar (145.00 psi) for the oil pressure control fitted between the pressure regulating valve and the discharge solenoid valve 18 bar (261.00 psi) (18,35 Km/cmÂ˛) 2.9 - 3.7 bar (42.05 - 53.65 psi)

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Transmission - Power shuttle transmission

Power Shuttle unit Method of operation Number of driven plates in each clutch Thickness of driven plates Driven plate material Number of driving plates in each clutch Driven disc thickness (each) Driving plate material Thickness of clutch assembly under a load of 1600 N (359.7 lb)

to reverse without having to stop the tractor or use the clutch pedal. by means of hand lever located under the steering wheel, to the left-hand side of the operator. 5 2.65 - 2.75 mm (0.10 - 0.11 in) N 401-2 5 2.15 - 2.25 mm (0.085 - 0.089 in) or 2.35 - 2.45 mm (0.093 - 0.096 in) steel 25.3 - 25.5 mm (1.000 - 1.004 in) (1)

(1) Value to obtain by varying the thickness of the driving plates.

Power shuttle transmission - Torque Power Shuttle transmission with creeper unit - 20X20 version T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

WLAPL4S21C501F

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Transmission - Power shuttle transmission

WLAPL4S21C303F

PARTS TO BE TIGHTENED Driven shaft manifold cover retaining nut (C1) Lubrication manifold retaining screw (C2) Clutch A bell housing retaining nut (C3) Flexible coupling retaining nut (C4) (•) Spacer retaining screw (C5) Spool valve cap ( (C1), 2) Clutch pressure control union ( (C2), 2) Oil fitting ( (C3), 2) Oil T fitting ( (C4), 2)

Tightening torque kgm Nm (lbft) 22 - 25 N·m (16.23 2,24 ÷ 2,55 - 18.44 lb ft) 22 - 25 N·m (16.23 2,24 ÷ 2,55 - 18.44 lb ft) 22 - 25 N·m (16.23 2,24 ÷ 2,55 - 18.44 lb ft) 30 - 34 N·m (22.13 3,06 ÷ 3,46 - 25.08 lb ft) 105 - 115 N·m 10,7 ÷ 11,7 (77.44 - 84.82 lb ft) 70 - 90 N·m (51.63 7,1 ÷ 9,2 - 66.38 lb ft) 22 - 29 N·m (16.23 2,24 ÷ 3 - 21.39 lb ft) 70 - 90 N·m (51.63 7,1 ÷ 9,2 - 66.38 lb ft) 48 - 66 N·m (35.40 4,9 ÷ 6,7 - 48.68 lb ft)

(•) Apply one or two drops of LOCTITE® 270 before tightening.

Power shuttle transmission - Special tools T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Power Shuttle transmission with creeper unit - 20X20 version 380000301: Rotating stand for overhaul operations.

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Transmission - Power shuttle transmission

380000291: Tool for A and B clutch springs. 380000290: Tool for fitting internal hub seals on A and B clutches. 380000296: Tool for fitting clutch driving shaft seal (with 380000258) 380000289: Limp home device. 380000843: Connector to access HH diagnostic programs.

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Transmission - Power shuttle transmission

TOOLS TO BE MADE IN THE WORKSHOP • 50169: Tool to be made to remove-install the clutch-gearbox casing on the engine (mark the tool with the no. 50169 − Measurements in mm) Make of UNI C40

50169

• 50223: Guide pins to be made to remove-install the cover of clutch A (mark the tool with the no. 50223 − Measurements in mm) Make of UNI C40

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Transmission - Power shuttle transmission

50223

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Transmission - Power shuttle transmission

Power shuttle transmission - Mechanical schema T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

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Transmission - Power shuttle transmission

TRANSMISSION DIAGRAM

WLAPL4S21C301H

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Transmission - Power shuttle transmission

(A): Transmission diagram 30 km/h (18.6 mph). (B): Transmission diagram 40 km/h (24.9 mph). (a): Front axle with 4--wheel drive. (b): Bevel drive. (c): Final reduction gears. (d): Differential lock. NOTE: (*): Reduction teeth, pinion â&#x20AC;&#x201D; ring gear, for 38" rear wheels.

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Transmission - Power shuttle transmission

Power shuttle transmission - Sectional view Longitudinal cross-sectional view of Power Shuttle gearbox. T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

SEZ21CAP3G-3

Forward gear clutch bell housing A.

Clutch A piston.

Clutch A.

Clutch A bottom / clutch B driving gear.

Clutch B bottom.

Reverse gear clutch B.

Clutch B piston.

Reverse driving gear / shaft.

Reverse driving gear.

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Transmission - Power shuttle transmission

10. Forward gear drive shaft. 11. Gearbox main shaft driving gear. 12. Flexible coupling. 13. Piston return springs in the neutral phase. 14. Lubrication manifold. 15. Transmission shaft lubrication line. 16. Reverse intermediate gears. 17. Keying ball. 18. Clutch casing transmission shaft. 19. Reverse idler gear shaft retaining pin. 20. Reverse idler gear. 21. Reverse idler gear shaft. 22. Bearing. NOTE: When fitting apply sealing compound to surfaces X

SEZ21CAP3F-4

Sealing compound application diagram for cover of clutch A. The types of sealing compound to apply are:( LOCTITE PLASTIC GASKET, RTV 1473, RHODORSILÂŽ CAF 1)

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Transmission - Power shuttle transmission

Power shuttle transmission - Static description T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

DESCRIPTION AND OPERATION Main hydraulic circuit (see Power shuttle transmission - Hydraulic schema Power Shuttle transmission -- Main hydraulic circuit (21.112)) The power steering pump draws filtered oil from the filter on the intake (17) it sends the oil to the power steering spool valve (6), the oil returning from the orbitrol goes to the transmission control spool valve (15) where it finds the pressure regulating valve governing the clutches and services. The valve regulates the oil at a pressure of 18 bar (261.00 psi) (18,35 kg/cm), afterwards the oil reaches the discharge solenoid valve that, finding it closed, does not continue; on the other side it reaches the services spool valve (13) through the outlet (b) .

Power Shuttle transmission -- Lubrication circuit (see Power shuttle transmission lubrication system - Hydraulic schema (21.100)) The excess oil goes into the lubrication circuit, the valve regulating the lubrication pressure ( (2) Power shuttle transmission - Hydraulic schema Power Shuttle transmission -- Main hydraulic circuit (21.112)) is on the manifold of the main shaft and sets the pressure to 2.9 - 3.7 bar (42.05 - 53.65 psi). Depending on the temperature of the oil it takes two specific routes: cold and therefore dense oil passes with difficulty through the cooler ( (1), Power shuttle transmission - Hydraulic schema Power Shuttle transmission -- Main hydraulic circuit (21.112)) then it opens the by--pass valve ( (11), Transmission control valve - Sectional view Power Shuttle transmission control valve. (21.134) ) and goes straight to lubrication. Hot fluid oil passes easily through the cooler so it leaves the spool valve through the pipe ( (e), Power shuttle transmission lubrication system - Hydraulic schema (21.100) ), it reaches the cooler ( (1), Power shuttle transmission - Hydraulic schema Power Shuttle transmission -- Main hydraulic circuit (21.112)), then returns to the spool valve on the pipe ( (h), Power shuttle transmission lubrication system - Hydraulic schema (21.100)) and goes straight to lubrication passing inside the by--pass valve; a portion crosses the pipe ( (i), Power shuttle transmission lubrication system - Hydraulic schema (21.100)) and reaches the power take--off ( (11), Power shuttle transmission - Hydraulic schema Power Shuttle transmission -- Main hydraulic circuit (21.112) ). The oil from the lubrication manifold lubricates the two clutches and the main shafts and, through the pipe ( (15), Power shuttle transmission Sectional view Longitudinal cross-sectional view of Power Shuttle gearbox. (21.112)), reaches the transmission shafts of the transmission and clutch casing and lubricates all the circuit as far as the pinion.

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Transmission - Power shuttle transmission

Power shuttle transmission - Hydraulic schema Power Shuttle transmission -- Main hydraulic circuit T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

WLAPL4S21C305F

Pressurized oil. Intake and discharge oil. Oil to lubrication. Oil at static rest. 1.

Heat exchanger.

Steering pump.

Steering cylinders.

Low pressure switch.

Front differential lock.

Power steering control valve.

Power take--off solenoid valve.

Differential lock solenoid valve.

Four--wheel drive pipe.

10. PTO brake. 11. Electrohydraulic PTO unit. 12. Rear differential lock. 13. User control valve. 14. Four wheel drive release solenoid valve. 15. Gearbox hydraulic control valve. 84568014 22/03/2013

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Transmission - Power shuttle transmission

16. Oil filter on delivery. 17. Oil filter on suction.

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Transmission - Power shuttle transmission

Power shuttle transmission - Sectional view Longitudinal cross--sectional view of Power Shuttle with Dual Command (2 Speed Power Shift) function.

SEZ21CAP4G-4

Clutch A cover.

Clutch A piston.

Clutch A.

Clutches A and B hub.

Clutch B.

Clutch B piston.

Clutch C.

Clutch D.

Clutches C and D springs.

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Transmission - Power shuttle transmission

10. Lubrication line. 11. Clutches A and B springs. NOTE: When fitting apply sealing compound to surfaces X.

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Transmission - Power shuttle transmission

Power shuttle transmission - Sectional view Cross--sectional view of Power Shuttle with Dual Command (2 Speed Power Shift) function. T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

SEZ21CAP4G-5

1. Lubrication oil pressure control valve. 2. Lubrication oil union. 3. Dual Command (2 Speed Power Shift) clutches (C and D) oil lines. 4. Reverse intermediate gear. 5. Gear pin (4). 6. Needle bearing. 7. Pin retaining screw (5). 8. Power Shuttle clutches (A and B) oil lines. 84568014 22/03/2013

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Transmission - Power shuttle transmission

Power shuttle transmission - Hydraulic schema with (2 Speed Power Shift) (24+24), 30 km/h (18.64 mph) version (Neutral). T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

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Transmission - Power shuttle transmission

SEZ21CAP4H-2OK

: Static rest oil (Neutral)

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Transmission - Power shuttle transmission

Power shuttle transmission - Hydraulic schema with Dual Command (2 Speed Power Shift) (24+24) - Lubrication circuit. T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

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Transmission - Power shuttle transmission

SEZ21CAP4H-3OK

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Transmission - Power shuttle transmission

: Pressurized oil : Discharge oil : Lubricating oil ( 2.9 - 3.7 bar (42.05 - 53.65 psi). 1.

Discharge oil

Oil to solenoid valves

Oil to the differential lock, four--wheel drive, power take--off and p.t.o. brake

Pump pressure oil

Hot oil to the heat exchanger

Pump pressure oil

Power take--off lubrication

Cold oil from the heat exchanger

Cold oil to lubrication

10. Cold oil to the by--pass valve

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Transmission - Power shuttle transmission

Power shuttle transmission - Hydraulic schema with Dual Command (2 Speed Power Shift) (24+24) - Clutch A in discharge T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

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Transmission - Power shuttle transmission

SEZ21CAP4H-5OK

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Transmission - Power shuttle transmission

: Pressurized oil : Discharge oil : Lubrication oil 1. Discharge oil 2. Oil to the differential lock, four--wheel drive, power take--off and p.t.o. brake 3. Oil from the pump

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Transmission - Power shuttle transmission

Power shuttle transmission - Hydraulic schema with Dual Command (2 Speed Power Shift) (24+24) - Clutch A under pressure. T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

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Transmission - Power shuttle transmission

SEZ21CAP4H-4OK

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Transmission - Power shuttle transmission

: Pressurized oil : Discharge oil : Lubrication oil 1. Lubrication oil 2. Oil to the differential lock, four--wheel drive, power take--off and p.t.o. brake 3. Oil from the pump

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Transmission - Power shuttle transmission

Power shuttle transmission - Hydraulic schema with Dual Command (2 Speed Power Shift) function (24+24) - Clutch C under pressure T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

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Transmission - Power shuttle transmission

WLAPL4S21C402H

Dual Command (2 Speed Power Shift) (24+24) - Clutch C under pressure

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Transmission - Power shuttle transmission

: Pressurised oil : Discharge oil : Lubrication oil 1. Discharge oil 2. Oil to the differential lock, four--wheel drive, power take--off and p.t.o. brake 3. Oil from the pump 4. Gearbox oil pressure switch 10 bar (145.00 psi) (10,2 Kg/cm2) .

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Transmission - Power shuttle transmission

Power shuttle transmission - Hydraulic schema with Dual Command (2 Speed Power Shift) function (24+24) - Clutch C in discharge T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

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Transmission - Power shuttle transmission

WLAPL4S21C403H

Dual Command (2 Speed Power Shift) (24+24) - Clutch C in discharge

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Transmission - Power shuttle transmission

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Transmission - Power shuttle transmission

Power shuttle transmission - Mechanical schema Power Shuttle transmission with Dual Command (2 Speed Power Shift) T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

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Transmission - Power shuttle transmission

WLAPL4S21C401H

transmission diagram of power shuttle and dual command (2 speed power shift)

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Transmission - Power shuttle transmission

(A): Transmission diagram 30 km/h. (B): Transmission diagram 40 km/h. (a): Front axle with 4--wheel drive. (b): Bevel drive. (c): Final reduction gears. (d): Differential lock. NOTE: (*) - Reduction teeth, pinion - ring gear, for 38". rear wheels

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Transmission - Power shuttle transmission

Power shuttle transmission - Static description power shuttle and dual command (2 speed power shift) - Speed Transmission. T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

4--speed gearbox with constant--mesh helical gears controlled by two synchronizers. The range gear has cascade-type constant--mesh spur gears. The range gear provides 3 gear ranges. The gearbox and the range gears are controlled by two independent levers located on the right--hand side of the operator. Lubrication is by means of the oil in the rear transmission/gearbox.

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Transmission - Power shuttle transmission

Power shuttle transmission - Static description power shuttle and dual command (2 speed power shift) - Power Shuttle unit. T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

NOTE: Refer tor Power shuttle transmission - Sectional view Longitudinal cross--sectional view of Power Shuttle with Dual Command (2 Speed Power Shift) function. (21.112). The Power Shuttle unit is composed of two multi--disk clutches in an oil bath located in the front part of the clutch casing, and is controlled by a control valve attached to the left-hand side of the clutch casing. This provides hydraulic control of 4 gears for each range, both forward and in reverse. Gear and range selection is carried out by means of the clutch pedal and operating the control levers, located on the right--hand side of the operator. The front clutch (A) commands the forward gears and the rear clutch (B) commands the reverse gears. Forward or reverse gear is selected by means of the lever under the steering wheel to the left of the operator; It is not necessary to depress the clutch pedal. The Power Shuttle unit provides 12 forward gears and 12 reverse gears.

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Transmission - Power shuttle transmission

Power shuttle transmission - Exploded view applying sealing compound.

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Transmission - Power shuttle transmission

SEZ21CAP4H-8

Applying sealing compound between the clutch housing -engine and rear transmission casing-gearbox. The types of sealing compounds to be applied are: LOCTITE PLASTIC GASKET, RTV 1473, RHODORSILÂ® CAF 1.

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Transmission - Power shuttle transmission

Power shuttle transmission - Mechanical schema of the Power Shuttle transmission with creeper unit - 20X20 version T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

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Transmission - Power shuttle transmission

WLAPL4S21C501H

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Transmission - Power shuttle transmission

(A). Transmission diagram 30 km/h (18.6 mph). (B). Transmission diagram 40 km/h (24.9 mph). (a). Front axle with 4--wheel drive. (b). Bevel drive. (c). Final reduction gears. (d). Differential lock. * - Reduction teeth, pinion â&#x20AC;&#x201D; ring gear, for 38" rear wheels.

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Transmission - Power shuttle transmission

Power shuttle transmission - Sectional view longitudinal Power Shuttle and creeper unit gearbox T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

SEZ21CAP5G-2

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Transmission - Power shuttle transmission

Forward gear shaft.

Reverse driving gear / shaft.

Reverse driven gear.

Creeper unit selector sleeve / driven gear.

Shaft / sleeve retaining half--rings (6).

Gearbox input shaft / sleeve.

Thrust washer limiting end float between shaft (8) and (6).

Gearbox main shaft.

Gearbox secondary shaft.

10. Creeper unit transmission thrust washer. 11. Creeper unit idler gear. 12. Ball coupling reverse idler gear to the shaft. 13. Fixed sleeve for direct gear engagement. 14. Reverse idler gear. 15. Reverser and creeper unit secondary shaft. 16. Reverse drive clutch. 17. Forward drive clutch. 18. Flexible coupling. 19. Reverse idler gear. 20. Shaft. 21. Bearing. 22. Shaft retaining pin. NOTE: When fitting apply sealing compound to surfaces X as shown in Clutch - Exploded view Sealing compound application diagram for clutch A cover of Power Shuttle transmission with creeper unit - 20X20 version (21.154).

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Transmission - Power shuttle transmission

Power shuttle transmission - Static description Power Shuttle transmission with creeper unit -- 20X20 version T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Power Shuttle unit (see Power shuttle transmission - Sectional view longitudinal Power Shuttle and creeper unit gearbox (21.112)) The Power Shuttle unit is composed of two multi--disk clutches in an oil bath located in the front part of the clutch casing, and is controlled by a control valve attached to the left--hand side of the clutch casing. This provides hydraulic control of 4 gears for each range, both forward and in reverse. Gear and range selection is carried out by means of the clutch pedal and operating the control levers, located on the right--hand side of the operator. The front clutch (A) commands the forward gears and the rear clutch (B) commands the reverse gears. Forward or reverse gear is selected by means of the lever under the steering wheel to the left of the operator; It is not necessary to depress the clutch pedal. The Power Shuttle unit provides 12 forward gears and 12 reverse gears.

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Transmission - Power shuttle transmission

Transmission housing - Remove To detach the clutch casing with the Power Shuttle unit remove the cab (see. Cab - Remove (90.150)) then proceed as follows: 1.

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

After disconnecting both battery cables (1) extract them from the support, also extract the cables for the battery cut-off switch, where applicable, and free them from any clamps as far as the engine.

Remove the battery retaining bracket (2), take out the battery (3) and its support (4).

WLAPL4S10C117A

MOIL12APL0000AA

MOIL12APL0001AA

Extract the pins (1) after having removed the split pins, detach the vertical tie--rods (2) from the lift arms and lower arms, then remove the anti--swing tie-rods (3).

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Transmission - Power shuttle transmission

Set mechanical stands under the final drive casings and take off the rear wheels.

Take out the screws (1) and remove the bracket (2) supporting the cab (right side).

Where applicable, remove the ventral spool valve together with its support and pipes.

Remove the front support of the fuel tank (1) and the relevant fasteners (2) . Afterwards take out the screws (3) fixing the rear support (4) and remove the support itself.

Detach the left cab support.

10.

SEZ21CAP4A-7

MOIL12APL0004AA

MOIL12APL0003AA

WLAPL4S10C112AA

Unscrew the front, central and rear bolts securing the drive shaft guard (1) .

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Transmission - Power shuttle transmission

11.

12.

13.

14.

Take off the circlip (2) and extract the sleeve (1) from the front axle.

WLAPL4S10C113AA

WLAPL4S10C114AA

Take off the circlip (2) and extract the sleeve (1) from the drive.

Take out the retaining bolts of the drive shaft central support (1) and remove the shaft together with its support.

WLAPL4S10C115AA

MOIL12APL0005AA

Detach the suction pipe of both pumps (1) and the delivery pipe to the lift (2) .

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Transmission - Power shuttle transmission

15.

16.

17.

18.

Remove the unions and disconnect the pipes delivering oil to the spool valve Power Shuttle (1) to the cooler (3) , the return (2) , oil delivery to the spool valve for the services (4) and lubrication to the power takeâ&#x2C6;&#x2019;off unit (5) . Remove the splitter pilot pipe (6) , if fitted.

MOIL12APL0006AA

MOIL12APL0007AA

MOIL12APL0008AA

MOIL12APL0009AA

Remove the union (1) and disconnect the front axle differential lock pipe (2).

Disconnect the electrical connections (1) of the controlling solenoid valve Power Shuttle , on the pressure sensor 3 bar (43.50 psi), temperature sensor and spool valve feed oil pressure sensor 10 bar (145.00 psi) .

Position the fixed stand (1) of tool 380000569 under the transmission casing, insert a wooden block between the stand and the transmission casing.

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Transmission - Power shuttle transmission

19.

20.

21.

22.

Position the mobile trolley (1) of tool 380000569 under the clutch casing (2), inserting a wooden block (3) between the trolley and the clutch casing then place a support column under the towbar.

MOIL12APL0010AA

MOIL12APL0011AA

MOIL12APL0012AA

MOIL12APL0013AA

Unscrew the clutch casing (1) retaining bolts from the rear transmission casing and separate the two casings.

Move the mobile trolley (3) under the sump, connect the chains of the lifting hook (1) to the clutch casing (2) and take up the strain with a hoist.

Unscrew the bolts and nuts securing the clutch casing (1) and the Power Shuttle unit to the engine (2) and remove the casing (1) .

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Transmission - Power shuttle transmission

Transmission housing - Install Re-assemble the clutch casing with the Power Shuttle unit, taking the following precautions. 1.

Before refitting the clutch casing to the engine and to the rear transmission casing carefully clean and degrease the mating surfaces and apply a bead of sealing compound of approximately 2 mm (0.0787 in) in diameter, as shown in the figure Power shuttle transmission - Exploded view (21.112)

Respect the tightening torques prescribed on page Power shuttle transmission - Torque (21.112)

Using the lifting hook and a hoist refit the clutch casing to the engine and secure by tightening the relative bolts or nuts to the prescribed torque value.

Position the mobile trolley of tool 380000569 under the clutch casing. Smear the splining grooves on the transmission and power takeâ&#x2C6;&#x2019;off drive shafts with NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE GREASE .

Move the engine--clutch casing unit towards the gearbox--transmission casing using tool 380000569 and acting on the front wheels.

Tighten the retaining bolts to the prescribed torque value and disconnect the lifting hook.

Remove the mobile trolley from under the clutch casing and the fixed stand from under the transmission--gearbox casing.

Connect the solenoid valve electrical connection to the Power Shuttle spool valve.

Refit the lines on the Power shuttle spool valve and the solenoid valve support, then refit the front differential lock piping.

10.

Assemble the gearbox--transmission oil heat exchanger piping and secure with the relative bracket.

11.

Fit the Power Shuttle spool valve feed line.

12.

Connect the two hydraulic pump pipes and the hydraulic lift delivery line.

13.

Fit the drive shaft and relative guard.

14.

Where applicable, fit the ventral spool valve.

15.

Mount the front brackets for supporting the cab.

16.

Mount the front and rear fuel tank support brackets.

17.

Fit the rear wheels, raising the tractor with a hoist and a nylon sling. Extract the two fixed stands from under the final drives and the column from under the towbar.

18.

Fit the two lift vertical tie--rods and the two anti-swing rods.

19.

Fit the cab as described in section Cab - Install (90.150)

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Transmission - Power shuttle transmission

20.

Make sure that all the transmission-gearbox drainage plugs are tightened and fill up with the quantities described in Section Consumables ()

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Index Transmission - 21 Power shuttle transmission - 112 Power shuttle transmission - Exploded view applying sealing compound. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Power shuttle transmission - General specification POWER SHUTTLE TRANSMISSION WITH CREEPER UNIT 20X20 VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Power shuttle transmission - General specification POWER SHUTTLE UNIT MAIN DATA (12 x 12) . . . . . . . . . . . 4 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Power shuttle transmission - General specification POWER SHUTTLE UNIT MAIN DATA (24 x 24) . . . . . . . . . . . 8 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - General specification TRANSMISSION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - General specification TRANSMISSION MAIN DATA (12 x 12) . . . . . . . . . . . . . . . . . . 4 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Power shuttle transmission - Hydraulic schema with Dual Command (2 Speed Power Shift) (24+24) - Clutch A under pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - Hydraulic schema Power Shuttle transmission -- Main hydraulic circuit . . . . . . . . . 25 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Power shuttle transmission - Hydraulic schema with (2 Speed Power Shift) (24+24), 30 km/h (18.64 mph) version (Neutral). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - Hydraulic schema with Dual Command (2 Speed Power Shift) (24+24) - Clutch A in discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - Hydraulic schema with Dual Command (2 Speed Power Shift) (24+24) - Lubrication circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - Hydraulic schema with Dual Command (2 Speed Power Shift) function (24+24) - Clutch C in discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - Hydraulic schema with Dual Command (2 Speed Power Shift) function (24+24) - Clutch C under pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - Mechanical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Power shuttle transmission - Mechanical schema Power Shuttle transmission with Dual Command (2 Speed Power Shift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - Mechanical schema of the Power Shuttle transmission with creeper unit - 20X20 version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Power shuttle transmission - Sectional view Cross--sectional view of Power Shuttle with Dual Command (2 Speed Power Shift) function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - Sectional view Longitudinal cross--sectional view of Power Shuttle with Dual Command (2 Speed Power Shift) function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Power shuttle transmission - Sectional view Longitudinal cross-sectional view of Power Shuttle gearbox. . . . . . 22 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Power shuttle transmission - Sectional view longitudinal Power Shuttle and creeper unit gearbox . . . . . . . . . . . . 57 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Power shuttle transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Power shuttle transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Power shuttle transmission - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Power shuttle transmission - Static description Power Shuttle transmission with creeper unit -- 20X20 version . 59 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

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Power shuttle transmission - Static description power shuttle and dual command (2 speed power shift) - Power Shuttle unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - Static description power shuttle and dual command (2 speed power shift) - Speed Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - Torque POWER SHUTTLE AND DUAL COMMAND (2 SPEED POWER SHIFT) . . 9 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Power shuttle transmission - Torque Power Shuttle transmission with creeper unit - 20X20 version . . . . . . . . . . . 14 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Power shuttle transmission - Torque power shuttle (12 x 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Transmission housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Transmission housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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Transmission - 21 Power shuttle transmission lubrication system - 104

T5.105 T5.115 T5.95

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Contents Transmission - 21 Power shuttle transmission lubrication system - 104

FUNCTIONAL DATA Power shuttle transmission lubrication system Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Transmission - Power shuttle transmission lubrication system

Power shuttle transmission lubrication system - Hydraulic schema Power Shuttle transmission -- Lubrication circuit

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Transmission - Power shuttle transmission lubrication system

WLAPL4S21C302H

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Transmission - Power shuttle transmission lubrication system

Pressure oil Discharge oil Lubrication oil. 1. Clutch engagement pressure regulating valve. 2. Lube pressure regulating valve. A. Oil from the power steering pump to the pressure regulating valve. B. Oil to the services control valve. C. Discharge oil. D. Discharge oil. E. Hot oil to the cooler. F. Lubricating oil (if hot it does not open the by--pass valve and goes to the cooler, if cold it goes straight to lubrication). G. Cold oil straight to lubrication H. Oil from cooler. I.

Oil to power take--off lubrication.

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Index Transmission - 21 Power shuttle transmission lubrication system - 104 Power shuttle transmission lubrication system - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Transmission - 21 Power shuttle transmission external controls - 134

T5.105 T5.115 T5.95

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Contents Transmission - 21 Power shuttle transmission external controls - 134

TECHNICAL DATA Transmission control levers Special tools Tool locking the main gear lever in the neutral position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools Tool locking the range selection lever in the neutral position. . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Reverser control lever Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Transmission control valve Sectional view Power Shuttle transmission control valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Sectional view of the Power Shuttle and Dual Command (2 Speed Power Shift) spool valve . . . . . . . . . . 9 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Sectional view Control valve of Power Shuttle transmission with creeper unit - 20X20 version . . . . . . . 10 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Transmission control levers Exploded view gear and range engagement device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Detailed view range and gear engagement flexible tie-rod assembly diagram . . . . . . . . . . . . . . . . . . . . . 13

SERVICE Transmission control levers Adjust gearbox and range gear coupling linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Transmission - Power shuttle transmission external controls

Transmission control levers - Special tools Tool locking the main gear lever in the neutral position.

WLAPL4S21C301G

NOTE: Tool to be made in the workshop, used to lock the main gear lever in the neutral position. (Distances in mm) Make of UNI C40

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Transmission - Power shuttle transmission external controls

Transmission control levers - Special tools Tool locking the range selection lever in the neutral position.

WLAPL4S21C302G

NOTE: Tool to be made in the workshop, used to lock the range selection lever in the neutral position. (Distances in mm) Make of UNI C40

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Transmission - Power shuttle transmission external controls

Reverser control lever - Dynamic description Gearbox operation The tractor features many transmission ratios thanks to the combined use of different levers, so that for each main gear it is possible to obtain different speeds.

Electrohydraulic shuttle control lever “ Power Shuttle ” The shuttle lever (3) , on the left of the steering wheel, is used to select the direction of travel, forward or reverse. To select the direction of travel, move the lever upwards and forwards for forward movement or backwards for reverse. The selected direction of travel is highlighted on the central display (see 2 ) of the instrument panel with symbols. When released, the shuttle lever will return to the rest position, even if the engagement switch remains on. To select neutral, depress the button (A) on the end of the lever. To invert the direction of travel simply reduce the tractor speed down to the minimum, then use the lever.

WLAPL4S21C318A

WLAPL4S21C310A

WLAPL4S21C313A

A " (N) " symbol can be seen on the display in the case in which: A - Request for starting with operator not sitting in the driving seat, without using the clutch pedal. The display lasts for 5 s , it is removed first if the operator moves the lever into neutral using the button ((A) , 1 ) on the lever of the shuttle . A - Request for starting without using the clutch pedal, with the handbrake pulled up. For the first 5 s it displays a " P ", afterwards a " N " appears on the lever of the shuttle . This view forces the operator to put the lever of the shuttle into neutral by pressing the button ((A) , 1 ).

Reactive switch On the left-hand upright there is a switch to select the reactivity of the electro-hydraulic shuttle. Depending on the position of the button there is a different response in the speed of inverting the direction of travel • Position ( (A) ) low reactivity • Position ( (B) ) high reactivity • Position ( (C) ) standard reactivity

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Transmission - Power shuttle transmission external controls

transmission and range gear lever By means of the transmission lever (1) it is possible to select the four gear ratios (1, 2, 3, 4). By means of the range gear lever (2) it is possible to select the different ranges. • I slow; • II medium; • III fast To change from one range to another, always stop the tractor; to change from one gear to another, use the main shift lever after fully depressing the clutch pedal (the tractor does not have to be halted as the gears are synchroengaged). NOTE: By using the main shift lever (1) , range gear lever (2) and shuttle lever ( (3) , 1 ) you can select 12 forward gears and 12 reverse gears.

WLAPL4S21C315A

WLAPL4S21C319A

WLAPL4S21C312A

Clutch pedal On the clutch pedal (1) there is a potentiometer (2) , which is like the clutch cable of a manual transmission; instead of transmitting the operator's actions through the flexible cable to the coupling of the mechanical clutch, it transmits electric pulses to the control unit. This receives a current of 5 V and a ground signal from the control unit, being a variable resistor, containing a slider, it sends a signal, to the control unit again, that varies according to the travel of the pedal. The operator, using the pedal, governs the control unit and with the speed of release - operation gives the clutch packing speed; with the pedal pressed it releases the clutches, vice versa with the pedal released it packs them obtaining the greatest traction. Again on the clutch pedal (1) there is also a switch, inside of which it has two contacts one normally open and one normally closed, this has a double function. - Switch normally closed with pedal released. It sends a current, coming from a fuse via the shuttle lever (with the lever in the rest position with the switch on), the control unit will use this current to feed the modulated solenoid valves that will send oil to the clutches. - Switch normally closed with pedal released. This is on the starting circuit between the key and the starting relay in series with the clutch of the power take−off; with the pedal pressed it closes and allows starting. NOTE: To start the engine you need to put the shuttle and power take−off ( PDF ) control levers into neutral, additionally you need to press the clutch pedal fully down.

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Transmission - Power shuttle transmission external controls

Clutch pedal adjustment On the clutch pedal (1) there are two adjustments to make, a mechanical one that consists in completely screwing the plug (2) onto the specific support and the cap (3) onto the pedal. A second electrical adjustment is made on the switch, entering the diagnostic programs of the gearbox control unit RW , in H7 and at channel ch1 , the display will show the percentage of travel at which the contact, connected to the switch control unit, passes from a state of open to a state of closed (with the pedal released). If this switchover does not happen, on releasing the pedal, at the percentage of 11 - 13 % of the travel use the adjuster (3) . NOTE: This adjustment is important because it affects the modulation of the clutches. The switch works in combination with the potentiometer: while the former supplies the current for the solenoid valves the latter, in a certain sense, provides their packing speed, by adjusting the pedal release time. If, for example, the switch closes at a much higher travel percentage there will be sharper modulation with the machine starting with a burst.

WLAPL4S21C320A

WLAPL4S21C311A

Because of an incorrect maneuver by the operator, the display could show CP , forcing the operator to press the clutch pedal, in the following cases. A - Request for starting without pressing the clutch pedal with the operator not sitting in the seat, after 5 s so N ( shuttle lever in neutral) has been removed, the display shows (CP) requiring the operator to press the pedal to re-enable the clutch. B - If the operator leaves the seat for longer than one second the transmission is disabled, when requesting starting without the clutch pedal.

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Transmission - Power shuttle transmission external controls

Transmission control valve - Sectional view Power Shuttle transmission control valve. T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

WLAPL4S21C304F

A. Hot oil to the cooler. B. Oil from the power steering to the spool valve. C. Oil on the pressure regulating valve 18 bar (261.00 psi) (18,3 Km/cmÂ˛) . D. Oil to the services control valve. 1.

Transmission oil temp sensor.

Unions for diagnostic tests on clutch lines.

Reverse proportional solenoid valve.

Forward proportional solenoid valve.

Dump solenoid valve.

Power shuttle spool valve supply fitting.

Heat exchanger hot oil delivery union.

Connections to the forward and reverse gear clutches.

Pressure relief valve spring.

10. Pressure relief valve spool. 11. Lubrication by--pass valve. 12. Cold oil lubrication line to the clutch casing. 13. Connection to the discharge. 14. Gearbox oil pressure switch 10 bar (145.00 psi) (10,2 Km/cmÂ˛) .

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Transmission - Power shuttle transmission external controls

Transmission control valve - Sectional view of the Power Shuttle and Dual Command (2 Speed Power Shift) spool valve T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

WLAPL4S21C402G

(1) Cooler oil delivery fitting-line. (2) Clutch A line pressure sensing pressure switch. (3) Clutch B line pressure sensing pressure switch. (4) Spool valve body. (5) Accumulator. (6) Clutch D pressure control fitting. (7) Clutch C pressure control fitting. (8) Clutch B pressure control fitting. (9) Clutch A pressure control fitting. (10) Clutch D solenoid valve.

(11) Clutch C control solenoid valve. (12) Clutch B solenoid valve. (13) Clutch A solenoid valve. (14) Pump delivery oil fitting. (15) Pressure control valve spring (16) (16) Oil pressure control valve. (17) Byâ&#x2C6;&#x2019;pass valve. (18) Byâ&#x2C6;&#x2019;pass valve spring. (19) Gearbox oil pressure switch 10 bar (145.00 psi).

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Transmission - Power shuttle transmission external controls

Transmission control valve - Sectional view Control valve of Power Shuttle transmission with creeper unit - 20X20 version T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

WLAPL4S21C304F

(a). - Hot oil to the cooler. (b). - Oil from the power steering to the spool valve. (c). - Oil on the pressure regulating valve 18 bar (261.00 psi) (18,3 Km/cmÂ˛) . (d). - Oil to the services spool valve. 1.

Transmission oil temperature sensor.

Unions for diagnostic tests on clutch lines.

Reverse solenoid valve (proportional).

Forward solenoid valve (proportional).

Dump solenoid valve.

Spool valve supply fitting Power Shuttle .

Heat exchanger hot oil delivery union.

Connections to the forward and reverse gear clutches.

Pressure relief valve spring.

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Transmission - Power shuttle transmission external controls

Transmission control levers - Exploded view gear and range engagement device

WLAPL4S21C305H

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Transmission - Power shuttle transmission external controls

(1) - Support assembly screws. (2) - Side bracket for linkage support. (3) - 3rd and 4th gear engagement plate.

(11) - Bushing. (12) - Support. (13) - Push-button wiring harness support bracket (for gear shift lever only). (4) - Engagement lever (gearbox or range gear). (14) - Nut fixing bracket (13) to the support. (5) - Pivot shaft. (15) - Screw fixing bracket (13) to the support. (6) - Spring pin. (16) - Shims. (7) - Return spring. (17) - Slow and fast range engagement plate. (8) - 1st and 2nd gear engagement plate. (18) - Mid-range engagement plate. (9) - Shim. (A) - Tractor direction in forward drive. (10) - Circlip. (B) - Engagement lever support fixing side. * - Where indicated apply grease (permanent and temperature resistant): KRITOX - GPL205

NOTE: The difference between the range and gear engagement mechanism lies in the different plates and levers. Only the gear engagement mechanism is fitted with the wiring support bracket (part (13) ) with the relevant fixing screw and nut (parts (14) and (15) ). After assembling the units: the range engagement unit is fitted on the tractor with the side (B) of the support in the opposite direction to that of the tractor in forward gear, while the gear engagement unit is fitted in the opposite direction to that one.

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Transmission - Power shuttle transmission external controls

Transmission control levers - Detailed view range and gear engagement flexible tie-rod assembly diagram

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Transmission - Power shuttle transmission external controls

WLAPL4S21C306H

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Transmission - Power shuttle transmission external controls

(a) - Range and gear engagement flexible tie-rod. (6) - Fixed sheath reaction device on the support in the cab. (b) - Range engagement lever. (7) - Flexible tie-rod engagement fork on the transmission side control lever. (c) - Gear engagement lever. (8) - Adjustable sheath reaction device on the transmission side bracket. (d) - Detail of gear engagement lever seen from (9) - Flexible sheath. (C) . (e) - Detail of transmission with the rod control (10) - Terminal distinguishing use of flexible tie-rod: linkage levers and related engagement control - White terminal for 1st and 2nd gear. forks. The range or gear being engaged should - Terminal with no color (there is actually no terminal) for 3rd be written on each lever. and 4th gear. - Red terminal for slow and fast range. - Blue terminal for medium range. (1) - Slow and fast range engagement tie-rod. (A) - Tractor direction in forward drive. (2) - Mid-range engagement tie-rod. (B) - Engagement lever support fixing side. (3) - 1st and 2nd gear engagement tie-rod. (C) - View of the gear engagement lever c. (4) - 3rd and 4th gear engagement tie-rod. (L) - Length of the flexible tie-rod: - Terminal for gear 1 and 2 coupling (L) = 1338 mm (52.6772 in). - Terminal for gear 3 and 4 coupling (L) = 1247 mm (49.0945 in). - Terminal for slow and fast range coupling (L) = 1410 mm (55.5118 in). - Terminal for mid-range coupling (L) = 1315 mm (51.7717 in). (5) - Flexible tie-rod coupling fork on the control lever in the cab. NOTE: The drawing shows the main gear lever (c) in the version with " Power Shuttle with HI - LO " 24X24, the same thing is no different in the other versions " Power Shuttle " 12X12 and " Power Shuttle with the Creeper" 20X20.

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Transmission - Power shuttle transmission external controls

Transmission control levers - Adjust gearbox and range gear coupling linkage. For the work on the cab seating, arrange the flexible tierods of the range lever (1) and gearbox (2) in the following manner: (3) - Mid-range coupling flexible tie-rod, blue marking. (4) - Slow and fast range coupling flexible tie-rod, red marking. (5) - 3rd and 4th gear coupling flexible tie-rod, with no marking. (6) - 1st and 2nd gear coupling flexible tie-rod, white marking. Pay attention not to get them crossed over.

WLAPL4S21C303A

NOTE: If, after detaching the cab and carrying out the relevant repairs, you need to lower it onto the transmission, proceed as follows to adjust the range and gear coupling flexible tie-rods. 1.

Make sure you have fitted the tie-rods in the right position (they are recognizable with a colored marking on the end of the sheath) and have locked the forks at the right distance (see figure Transmission control levers - Detailed view range and gear engagement flexible tie-rod assembly diagram (21.130) ).

Gear lever locking in neutral 2.

Extract the cap (1) of the main gear lever from the frame, then overturn it upwards, put the lever into the neutral position.

Take the gear lever locking tool (see n (1) , 3 ), insert it into the space between the gear coupling plates and the front of the cap retaining frame.

Position the tool, as shown in 4 , then fasten it with the two screws (3) on the top of the tool.

WLAPL4S21C307A

WLAPL4S21C301A

(1) - Gear lever locking tool

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Transmission - Power shuttle transmission external controls

Take the tool (1) , insert it into the front of the support (as shown in 4 ). Find two M5 screws (2) of a sufficient length that if screwed in completely, on the top of the tool, they can enter the holes (3) of the plates, locking them in neutral.

WLAPL4S21C301B

WLAPL4S21C308A

WLAPL4S21C309A

Range lever locking in neutral 5.

Extract the cap (1) of the range coupling lever from the frame, then overturn it upwards, put the lever into the neutral position.

Take the gear lever locking tool (see n (1) , fig. 8 ), insert it into the space between the gear coupling plates and the front of the cap retaining frame.

Position the tool, as shown in figure 6 , then fasten it with the screw (3) on the front of the support.

Lock the two coupling plates in neutral by inserting the screw (1) in the two slots on the front of the plates and screw it in on the inside of the tool.

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Transmission - Power shuttle transmission external controls

(1) - Range lever locking tool (2) - Plate retaining screw

WLAPL4S21C302A

WLAPL4S21C302B

WLAPL4S21C304A

- Take the tool (1) , rest it on the front of the support (as shown in 8 ). - Find a M5 screw of a sufficient length that if screwed in completely, on the top of the tool, into the hole (2) it can enter the hole for fixing the bracket (see detail (13) , fig. Transmission control levers - Exploded view gear and range engagement device (21.114) ) supporting the button wiring (this part is not present on this lever), locking the tool to the support. - Insert the screw (3) on the tool, this will pass through the two slots on the front of the coupling plates, once set in neutral; screw in the screw on the inside of the tool 9.

After locking the gear coupling and range gear coupling levers in the neutral position, proceed to connect the end of the flexible tie-rods to the range and gear coupling levers, on the transmission.

10.

Make sure that all four coupling levers on the transmission are in the neutral position.

11.

Take the flexible tie-rod with no colored marking, the one for gear 3 and 4 coupling, insert it, between the two nuts located at the end of the sheath, on the first reaction bracket (2) , the very front one.

12.

Then move the fork (3) near to the external coupling lever (4).

13.

While keeping the front nut (1) and its washer always in contact with the bracket (2) , screw on or unscrew the nut until the hole on the fork (3) tallies with the hole on the lever (4) .

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Transmission - Power shuttle transmission external controls

14.

15.

16.

Now insert the safety pin (1) .

WLAPL4S21C305A

WLAPL4S21C306A

Using two appropriate hexagonal wrenches keep the nut (1) stationary, then move the nut (2) near and tighten it.

Proceed with the operations from point 11 to point 15 for all the other 3 flexible cables.

NOTE: As regards the colored markings and the distances at which to fasten the forks and the coupling between the flexible cables and reaction brackets make reference to Transmission control levers - Detailed view range and gear engagement flexible tie-rod assembly diagram (21.130) .

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Index Transmission - 21 Power shuttle transmission external controls - 134 Reverser control lever - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Transmission control levers - Adjust gearbox and range gear coupling linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Transmission control levers - Detailed view range and gear engagement flexible tie-rod assembly diagram . . . 13 Transmission control levers - Exploded view gear and range engagement device . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Transmission control levers - Special tools Tool locking the main gear lever in the neutral position. . . . . . . . . . . . . 3 Transmission control levers - Special tools Tool locking the range selection lever in the neutral position. . . . . . . . 4 Transmission control valve - Sectional view Control valve of Power Shuttle transmission with creeper unit - 20X20 version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Transmission control valve - Sectional view Power Shuttle transmission control valve. . . . . . . . . . . . . . . . . . . . . . . 8 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Transmission control valve - Sectional view of the Power Shuttle and Dual Command (2 Speed Power Shift) spool valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

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Transmission - 21 Transmission/Rear drive internal components - 148

T5.105 T5.115 T5.95

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Contents Transmission - 21 Transmission/Rear drive internal components - 148

FUNCTIONAL DATA Transmission/Rear drive internal components Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Transmission internal controls Sectional view gear and range engagement devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Transmission - Transmission/Rear drive internal components

Transmission/Rear drive internal components - Sectional view Longitudinal cross-section of gearbox-transmission (12 x 12)

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Transmission - Transmission/Rear drive internal components

WLAPL4S27C102H

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Transmission - Transmission/Rear drive internal components

(1)series tractor. (2)series tractor. (3)series tractor. (4)series tractor. (5)series tractor. (6)series tractor.

- Gearbox input shaft. - Bushing. - 3rd and 4th gear selector fork. - Power take-off shaft. - 1st and 2nd gear selector fork. - Detent ball and spring.

(7)series tractor. - Range gear driving shaft. (8)series tractor. - Gearbox neutral sensor G. (9)series tractor. - Selector fork and sleeve for medium range. (10)series tractor. - Driving gear for medium range and ground speed PTO. (11)series tractor. - PTO shaft splined coupling. (12)series tractor. - Ground speed PTO engagement sleeve. (13)series tractor. - Differential lock selector rod and fork.

(14)series tractor. - Gearbox input shaft nut. (15)series tractor. - Bushing. (16)series tractor. - 3rd and 4th gear synchronizer. (17)series tractor. - 1st and 2nd gear synchronizer. (18)series tractor. - Gearbox driven shaft. (19)series tractor. - Selector fork and sleeve for slow and fast range. (20)series tractor. - Slow range driven gear. (21)series tractor. - Pinion bearing pre-load nut. (22)series tractor. - Lock washer for bearing pre-load nut. (23)series tractor. - Driven gear for medium range and front axle drive. (24)series tractor. - Pinion. (25)series tractor. - Differential side gears shaft. (26)series tractor. - Differential side gear.

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Transmission - Transmission/Rear drive internal components

Transmission internal controls - Sectional view gear and range engagement devices

WLAPL4S27C103H

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Transmission - Transmission/Rear drive internal components

WLAPL4S27C104H

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Transmission - Transmission/Rear drive internal components

(1) . - 1 and 2 gear engagement fork.

(16) . - Slow and fast range engagement unit control device. (2) . - 1 and 2 gear engagement rod. (17) . - Slow and fast range engagement external lever. (3) . - 4 and 5 gear engagement rod. (18) . - Mid-range engagement external lever. (4) . - 4 and 5 gear engagement fork. (19) . - 1 and 2 gear engagement external lever. (5) . - Mid-range engagement rod. (20) . - 3 and 4 gear engagement external lever. (6) . - Mid-range sensor feeler. (21) . - Slow and fast range engagement internal lever. (7) . - Slow and fast range engagement rod. (22) . - Mid-range engagement internal lever. (8) . - Slow and fast range feeler. (23) . - 1 and 2 gear engagement internal lever. (9) . - Slow and fast range engagement fork. (24) . - 3 and 4 gear engagement internal lever. (10) . - Slow and fast range engagement unit. (25) . - Gasket. (11) . - Mid-range engagement unit. (26) . - Bearing. (12) . - Mid-range engagement fork. (27) . - Return spring. (13) . - Gear neutral feeler. (28) . - Gearbox cover. (14) . - 3 and 4 gear fork control device. (29) . - Flexible bracket reaction bracket unit. (15) . - Safety pawl (prevents engaging two gears at the (30) . - Safety pawl (prevents engaging two ranges at same time). the same time).

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Index Transmission - 21 Transmission/Rear drive internal components - 148 Transmission internal controls - Sectional view gear and range engagement devices . . . . . . . . . . . . . . . . . . . . . . . . 6 Transmission/Rear drive internal components - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Transmission - 21 Power shuttle transmission internal components - 154

T5.105 T5.115 T5.95

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Contents Transmission - 21 Power shuttle transmission internal components - 154

FUNCTIONAL DATA Clutch Static description Clutch A at rest / engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic schema Power Shuttle transmission -- Clutch A at rest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic schema Power Shuttle transmission -- Clutch A engaged. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exploded view Sealing compound application diagram for clutch A cover of Power Shuttle transmission with creeper unit - 20X20 version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Gears, shaft, and bearings Static description Power Shuttle transmission with creeper unit -- 20X20 version . . . . . . . . . . . . . . . . . . 10 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Transmission drive and driven shafts Sectional view Longitudinal section of the main shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) . . . . . . 12 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

SERVICE Clutch Disassemble Clutch casing with power shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Assemble refit the clutch casing with power shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Disassemble Clutch A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Assemble Clutch A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Disassemble Clutch B (and assemble) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Disassemble Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units . . . . . 27 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Assemble Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units . . . . . . . 34 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Disassemble Clutch A of Dual command (2 speed power shift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Disassemble Clutch B of Dual command (2 speed power shift) + Assemble . . . . . . . . . . . . . . . . . . . . . . . 37 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Assemble Clutch A of Dual command (2 speed power shift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

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Disassemble Clutch casing with power shuttle and creeper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Assemble Clutch casing with power shuttle and creeper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Transmission drive and driven shafts Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Disassemble . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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Transmission - Power shuttle transmission internal components

Clutch - Static description Clutch A at rest / engaged (see Clutch - Hydraulic schema Power Shuttle transmission -- Clutch A at rest. (21.154) and Clutch - Hydraulic schema Power Shuttle transmission -- Clutch A engaged. (21.154) ) With the machine stationary and the tractor running, the oil under pressure reaches the base of the discharge solenoid valve (see Clutch - Hydraulic schema Power Shuttle transmission -- Clutch A at rest. (21.154)). Since this solenoid valve is normally on discharge all the rest of the control valve is kept in this condition via the pipe ( (c), Clutch - Hydraulic schema Power Shuttle transmission -- Clutch A at rest. (21.154) and Clutch - Hydraulic schema Power Shuttle transmission -- Clutch A engaged. (21.154)). On deciding to start driving the tractor, either by using the clutch pedal and moving the shuttle lever into forward or reverse gear or by using only the shuttle lever, a signal is sent to the control unit that opens immediately energizing the discharge solenoid valve that opens and sends the oil under pressure into the pipe connected with the end portion of the clutch control solenoid valves. If forward gear is selected the control unit sends a signal to the solenoid valve of clutch A that modulates making the oil pass gradually and packing the clutch A moving the tractor forwards (see Clutch - Hydraulic schema Power Shuttle transmission -- Clutch A engaged. (21.154)). In a similar manner it works in reverse gear as soon as the control unit controls the discharge solenoid valve and proportionally controls the reverse gear solenoid valve.

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Transmission - Power shuttle transmission internal components

Clutch - Hydraulic schema Power Shuttle transmission -- Clutch A at rest.

SEZ21CAP3G-6OK

Pressurized oil Discharge oil Lubricating oil (1): Dump solenoid valve. (2): Forward solenoid valve (proportional). (3): Reverse solenoid valve (proportional). (4): Reverse gear pipe diagnosis connector. (5): Temperature sensor.

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Transmission - Power shuttle transmission internal components

(6): Pipe to the reverse gear clutch. (a): Oil from the power steering pump to the pressure regulating valve. (b): Oil to the services control valve. (c): Discharge oil

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Transmission - Power shuttle transmission internal components

Clutch - Hydraulic schema Power Shuttle transmission -- Clutch A engaged.

WLAPL4S21C304H

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Transmission - Power shuttle transmission internal components

Pressurized oil Discharge oil Lubricating oil (1). Dump solenoid valve. (2). Forward solenoid valve (proportional). (3). Forward solenoid valve (proportional). (4). Reverse solenoid valve (proportional). (5). Temperature sensor. (6). Pipe to the reverse gear clutch. (a). Oil from the power steering pump to the pressure regulating valve. (b). Oil from the power steering pump to the pressure regulating valve. (c). Discharge oil

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Transmission - Power shuttle transmission internal components

Clutch - Exploded view Sealing compound application diagram for clutch A cover of Power Shuttle transmission with creeper unit 20X20 version T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

SEZ21CAP5F-3

The types of sealing compounds to be applied are LOCTITE PLASTIC GASKET, RTV 1473, RHODORSILÂ® CAF 1.

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Transmission - Power shuttle transmission internal components

Gears, shaft, and bearings - Static description Power Shuttle transmission with creeper unit -- 20X20 version T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Speed Transmission 4--speed gearbox with constant--mesh helical gears controlled by two synchronizers. The range gear has cascade--type constant--mesh spur gears. The range gear provides 3 gear ranges. The gearbox and the range gears are controlled by two independent levers located on the right--hand side of the operator. Lubrication is by means of the oil in the rear transmission / gearbox.

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Transmission - Power shuttle transmission internal components

Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

SEZ21CAP3F-5

Gearbox driving gear thrust circlip.

Reverse driving gear rear thrust circlip.

Reverse driving gear.

Reverse gear shaft internal bearing retaining circlip.

Reverse driving gear / shaft.

Forward gear shaft.

Bearing.

Circlip.

Forward gear clutch driven hub A.

10. Bearing. 11. Circlip. 12. Reverse gear clutch hub retaining circlip B. 13. Circlip. 14. Forward gear clutch A bottom / reverse gear clutch B driving hub. 15. Retaining circlip part (14). 16. Forward gear clutch A bell housing circlip.

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Transmission - Power shuttle transmission internal components

Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

SEZ21CAP4F-1

Gearbox driving gear thrust circlip.

Reverse driving gear rear thrust circlip.

Reverse driving gear.

Reverse gear shaft internal bearing retaining circlip.

Reverse driving gear / shaft.

Forward gear shaft.

Bearing.

Circlip.

Forward gear clutch driven hub A.

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Transmission - Power shuttle transmission internal components

Clutch - Disassemble Clutch casing with power shuttle T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

NOTE: In order to work on the reverser--creeper unit first detach the cab or platform as described in the cab disassembly or platform disassembly chapter, then remove the clutch casing as described in Clutch - Disassemble Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units (21.154) .

Fix the gearbox to the rotating stand 380000301 (1) using the brackets.

Unscrew the retaining screws and remove the control valve (1).

SEZ21CAP3A-4

SEZ21CAP3A-34

SEZ21CAP3A-35

Extract the oil drainage union (1).

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Transmission - Power shuttle transmission internal components

Take out the screws fastening the cover of the clutch ( (1), Power shuttle transmission - Sectional view Longitudinal cross-sectional view of Power Shuttle gearbox. (21.112)) screw three screws into the extraction holes (2) and remove the cover (1) and clutch A.

SEZ21CAP3A-5

SEZ21CAP3A-6

SEZ21CAP3A-36

SEZ21CAP3A-37

Remove the circlip (1) locking clutch B on the related shaft.

Extract clutch B (1) from the shaft and remove.

Unscrew the retaining screws and the lubrication manifold (1) together with the transmission shaft unit lubrication line ( (15), Power shuttle transmission - Sectional view Longitudinal cross-sectional view of Power Shuttle gearbox. (21.112)).

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Transmission - Power shuttle transmission internal components

10.

11.

Take off the nuts fastening the transmission shaft lubrication cover (1) and then remove it.

SEZ21CAP3A-7

SEZ21CAP3A-8

Remove the circlip (1), transmission shaft fastener ( (18), Power shuttle transmission - Sectional view Longitudinal cross-sectional view of Power Shuttle gearbox. (21.112)), together with the washer.

Extract the gearbox main shaft driving gear (1) ( (11), Power shuttle transmission - Sectional view Longitudinal cross-sectional view of Power Shuttle gearbox. (21.112)).

SEZ21CAP3A-38

SEZ21CAP3A-39

Using a suitable punch, tap the transmission shaft (1) and extract it from the related bearing.

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Transmission - Power shuttle transmission internal components

12.

13.

14.

15.

From the back, remove the transmission shaft (1) together with the reverse intermediate gear and the keying ball ( (16), Power shuttle transmission Sectional view Longitudinal cross-sectional view of Power Shuttle gearbox. (21.112)) between the two.

SEZ21CAP3A-62

SEZ21CAP3A-9

SEZ21CAP3A-40

SEZ21CAP3A-41

Remove the grub screw (1) on the reverse idler gear unit pin.

Working from the back of the clutch casing, extract the reverse idler gear together with the pin (1) and the related bearing and thrust washer.

Using a suitable punch, tap the driving shaft (1).

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Transmission - Power shuttle transmission internal components

16.

Remove the driving shaft (1), working from the rear side of the clutch casing.

SEZ21CAP3A-10

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Transmission - Power shuttle transmission internal components

Clutch - Assemble refit the clutch casing with power shuttle T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

- For the correct orientation of the various parts, refer to the illustrations in Power shuttle transmission - Sectional view Longitudinal cross-sectional view of Power Shuttle gearbox. (21.112) and Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. (21.154). - Before refitting the casings, supports and covers clean and de--grease the mating surfaces and apply sealing compound (approx. 2 mm (0.08 in) in diameter) as shown in Power shuttle transmission - Sectional view Longitudinal cross-sectional view of Power Shuttle gearbox. (21.112)figure 2. - Respect the tightening torques prescribed on Power shuttle transmission - Torque power shuttle (12 x 12) (21.112) . - Mount the driving shaft. - Fit the thrust washer, gear unit and reverse pin, securing in position with the screw. - Mount the clutch casing transmission shaft and lock it from the front with the washer and circlip. - Mount the transmission shaft lubrication cover and then screw on the retaining nuts. - Assemble and secure the lubrication manifold, complete with the transmission shaft lubrication line. - Position clutch B on the shaft and secure with the circlip. - Assemble and secure the cover and clutch A. - Insert the oil drainage union. - Re--fit the control valve.

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Transmission - Power shuttle transmission internal components

Clutch - Disassemble Clutch A. T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Remove the circlip (1) retaining the forward gear clutch A bottom / reverse gear clutch driving hub B ( (3), Power shuttle transmission - Sectional view Longitudinal cross-sectional view of Power Shuttle gearbox. (21.112)).

Recover the unit (1) composed of: - forward gear clutch A bottom / reverse gear clutch driving hub B ( (14), Transmission drive and driven shafts Sectional view Longitudinal section of the main shaft. (21.154))- bearing ( (10), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. (21.154)) of forward gear clutch A driven hub ( (9), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. (21.154))- circlip retaining bearing on the hub ( (11), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. (21.154))- circlip retaining bearing (13), ( Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. (21.154)) on forward gear clutch A bottom part (14) ( Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. (21.154))

SEZ21CAP3A-22

SEZ21CAP3A-11

SEZ21CAP3A-42

Remove the clutch A disk assembly (1), the separating springs and the anti--rotation pin.

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Transmission - Power shuttle transmission internal components

Using a screwdriver (1) remove the seal and the circlip ( (16), Transmission drive and driven shafts Sectional view Longitudinal section of the main shaft. (21.154)), with an appropriate pair of pliers.

SEZ21CAP3A-43

SEZ21CAP3A-12

SEZ21CAP3A-13

SEZ21CAP3A-44

Using a brass punch, tap on the hub (1) on clutch casing A.

Extract the cover (1) and remove the clutch casing A (2).

Position the clutch casing A (1) under a press and, using tool 380000291 (2) and adapter, compress the springs, remove the stop ring (3) and remove the Belleville washer.

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Transmission - Power shuttle transmission internal components

Replacing the seal on the clutch casing internal hub. 8.

10.

Position the O--Ring seal (1) in the relative seat on the clutch casing internal hub.

SEZ21CAP3A-45

SEZ21CAP3A-14

Position the external ring (1) of the seal on the guide on tool 380000290 (2).

Position the guide (2) on tool 380000290 on the clutch casing internal hub and push the ring (3) into position using the press (1) on tool 380000290.

SEZ21CAP3A-15

Next operation: Clutch - Assemble Clutch A (21.154) .

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Transmission - Power shuttle transmission internal components

Clutch - Assemble Clutch A T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Position the clutch casing A (1) under a press and, using tool 380000291 (2) and adapter, compress the Belleville springs and fit the spring stop ring.

SEZ21CAP3A-44

SEZ21CAP3A-47

SEZ21CAP3A-16

SEZ21CAP3A-17

Fit the casing (1) of the clutch A on its cover (2) and secure it with the circlip, then fit the seal.

Assemble the clutch disk assembly on the clutch casing A as described here: - Insert the first metal disk (2) on the casing (1) of the clutch A.

On the casing (1) of the clutch A, make a reference mark (2) to time the splits of the springs during the assembly operation.

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Transmission - Power shuttle transmission internal components

Do the timing of the swings (1) and splits (2) of the springs as shown in the figure.

SEZ21CAP3A-48

SEZ21CAP3A-49

SEZ21CAP3A-18

SEZ21CAP3A-50

Insert the first spring on the casing (1) of the clutch A, keeping the split of the spring (2) timed with the reference mark (3) made beforehand.

Insert the first clutch disk (2) on the casing (1) of the clutch A, centring the spring (3) previously mounted on the outer edge of the disk (2).

Insert the second metal disk (2) on the casing (1) of the clutch A.

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Transmission - Power shuttle transmission internal components

Insert the second clutch disk (2) on the casing (1) of the clutch A, centring the spring (3) previously mounted on the outer edge of the disk (2). - Complete fitting the disk assembly and clutch springs A on the casing following the above method.

SEZ21CAP3A-51

10.

11.

12.

Inside the split in the separating springs, insert a pin (1) into the space between the teeth of the disks keyed onto the clutch bell housing. This is to prevent some springs from turning and not respecting the timing.

Refit the unit (1) composed of: - forward gear clutch A bottom / reverse gear clutch driving hub B ( (14), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. (21.154)) - bearing ( (10), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. (21.154)) of clutch A driven hub ( (9), Transmission drive and driven shafts Sectional view Longitudinal section of the main shaft. (21.154)) - circlip retaining bearing on the hub ( (11), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. (21.154)) - circlip retaining bearing on part (14) ( (13), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. (21.154))

SEZ21CAP3A-20

SEZ21CAP3A-11

SEZ21CAP3A-22

Fit the circlip (1) retaining the unit previously fitted inside the clutch A.

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Transmission - Power shuttle transmission internal components

Clutch - Disassemble Clutch B (and assemble) T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Remove the circlip (1), the disk assembly, separating springs and the anti--rotation pin.

Carry out operations no. 3. and from no. 7. to no. 10. described ( Clutch - Disassemble Clutch A. (21.154)) and from operation 1 to 9 described ( Clutch - Assemble Clutch A (21.154)) for clutch A to correctly disassemble/assemble the disks and the springs of the clutch B.

In a similar manner to operation 10 of clutch A assembly ( Clutch - Assemble Clutch A (21.154)), insert the pin into the space between the teeth of the metal disk keyed onto the clutch B bell housing, left free by the split in the springs.

SEZ21CAP3A-53

SEZ21CAP3A-23

SEZ21CAP3A-54

Take great care over positioning the disk of clutch B. One tooth up it has a retaining pin (1), the position of this tooth must be very far from the space where the pin is inserted described in the preceding operation.

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Transmission - Power shuttle transmission internal components

Insert the retaining circlip with the pliers. Keep the tooth with the pin in the middle of the split in the ring. The pin will prevent the ring from turning and therefore the pin from coming out that was inserted in 3.

SEZ21CAP3A-24

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Transmission - Power shuttle transmission internal components

Clutch - Disassemble Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Fix the gearbox to the rotating stand 380000301 (1) using the front and rear brackets.

SEZ21CAP4A-18

SEZ21CAP4A-74

SEZ21CAP4A-75

Unscrew the retaining screws and remove the control valve (1).

Extract the oil drainage union (1).

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Transmission - Power shuttle transmission internal components

Unscrew the retaining screw, detach the bracket (1) and remove the control valve/internal manifold connecting lines (2).

SEZ21CAP4A-19

SEZ21CAP4A-20

SEZ21CAP4A-76

SEZ21CAP4A-77

Remove the seal and the snap ring (1).

Take out the screws fastening the cover (1) of the clutch A, screw three screws into the extraction holes (2) and remove the cover (1).

Remove the retaining ring (1) fastening the clutch B.

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Transmission - Power shuttle transmission internal components

10.

11.

Extract clutch B (1) from the shaft and remove.

SEZ21CAP4A-21

SEZ21CAP4A-22

Unscrew the retaining screws and the lubrication manifold (1) together with the Dual Command (2 Speed Power Shift) clutch unit lubrication lines.

Unscrew the retaining screws and remove the Dual Command (2 Speed Power Shift) clutch shaft manifold cover (1).

SEZ21CAP4A-78

SEZ21CAP4A-79

Remove the Dual Command (2 Speed Power Shift) clutch shaft bearing (1).

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Transmission - Power shuttle transmission internal components

12.

13.

Position and secure tool 380000244 (1) on the clutch casing.

SEZ21CAP4A-24

SEZ21CAP4A-80

SEZ21CAP4A-81

Remove the nut on the Dual Command (2 Speed Power Shift) clutch shaft.

14.

Extract the manifold ring (1) from the dual command clutches shaft.

15.

Disassemble tool 380000244 ( (1), 12)

16.

SEZ21CAP4A-23

Take out the retaining bolts and remove the bracket (1).

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Transmission - Power shuttle transmission internal components

17.

18.

19.

20.

Remove the snap ring (1) on the driving shaft.

SEZ21CAP4A-25

SEZ21CAP4A-26

SEZ21CAP4A-82

SEZ21CAP4A-83

Using a puller (1) extract the gear (2) with its bearing.

Using a suitable punch, tap the dual command clutches shaft (1) and extract the bearing.

Remove the shaft together with the Dual Command (2 Speed Power Shift) clutches (1).

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Transmission - Power shuttle transmission internal components

21.

22.

23.

24.

Remove the grub screw (1) on the reverse gear unit pin.

SEZ21CAP4A-27

SEZ21CAP4A-28

SEZ21CAP4A-29

SEZ21CAP4A-30

Working from the front side of the clutch casing, tap the reverse gear unit pin (1) with a punch and remove the unit from the rear side, together with the thrust washer (2).

Using a suitable punch, tap the driving shaft (1).

Remove the driving shaft (1), working from the rear side of the clutch casing.

Next operation: Transmission drive and driven shafts - Disassemble . Disassembly (21.154). Next operation: Transmission drive and driven shafts - Disassemble (21.154). 84568014 22/03/2013

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Transmission - Power shuttle transmission internal components

Next operation: Clutch - Assemble Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units (21.154) .

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Transmission - Power shuttle transmission internal components

Clutch - Assemble Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

NOTE: For the correct orientation of the various parts, refer to the illustrations in figs. Power shuttle transmission Sectional view Longitudinal cross--sectional view of Power Shuttle with Dual Command (2 Speed Power Shift) function. (21.112) and Power shuttle transmission - Sectional view Cross--sectional view of Power Shuttle with Dual Command (2 Speed Power Shift) function. (21.112). 1.

Before refitting the casings, supports and covers clean and de--grease the mating surfaces and apply sealing compound (approx. 2 mm (0.08 in) in diameter) as shown in Power shuttle transmission - Exploded view applying sealing compound. (21.112).

Respect the tightening torques prescribed in Power shuttle transmission - Torque POWER SHUTTLE AND DUAL COMMAND (2 SPEED POWER SHIFT) (21.112) .

Mount the driving shaft.

Fit the thrust washer, gear unit and reverse pin, securing in position with the screw.

Assemble the Dual Command (2 Speed Power Shift) shaft and lock in position with tool 380000244.

Assemble and secure the bracket with guard on the Dual Command (2 Speed Power Shift) clutch shaft.

Fit the manifold ring on the dual command clutches shaft, tighten and secure the nut.

Remove tool 380000244 and fit the bearing in the seat on the Dual Command (2 Speed Power Shift) clutch shaft.

Assemble and secure the manifold cover on the Dual Command (2 Speed Power Shift) clutch shaft.

10.

Assemble and secure the lubrication manifold, complete with Dual Command (2 Speed Power Shift) clutch unit lubrication line.

11.

Position clutch B on the shaft and secure with the circlip.

12.

Assemble and secure the cover and clutch A.

13.

Fit the seal and the snap ring on the clutch A cover.

14.

Insert the control valve--internal manifold connecting lines, position and secure the relative bracket.

15.

Insert the oil drainage union.

16.

Position and secure the control valve.

17.

Fit the driving shaft rear gear and related bearing and hold it with the circlip.

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Transmission - Power shuttle transmission internal components

Clutch - Disassemble Clutch A of Dual command (2 speed power shift) T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Remove the circlip (1) retaining the forward gear clutch A bottom / reverse gear clutch driving hub B ( (14), Transmission drive and driven shafts Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154)).

Recover the unit (1)composed of: - forward gear clutch A bottom / reverse gear clutch driving hub B ( (14), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154)) - bearing ( (10), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154))>) - of the forward gear clutch A driven hub ( (9), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154)) - circlip retaining bearing on the hub ( (11), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154)) - circlip retaining bearing on part (14) ( (13), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154))

SEZ21CAP4A-85

SEZ21CAP4A-86

SEZ21CAP4A-39

Remove the clutch A disk assembly (1), the separating springs and the anti-rotation pin

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Transmission - Power shuttle transmission internal components

Using a brass punch, tap on the hub (1) on clutch casing A after removing the circlip ( (16), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154)), with an appropriate pair of pliers.

SEZ21CAP4A-40

SEZ21CAP4A-87

SEZ21CAP4A-88

Extract the cover (1) and remove the clutch casing A (2).

Position the clutch casing A (1) under a press and, using tool 380000291 (2) and adapter, compress the springs, remove the stop ring (3) and remove the Belleville washer.

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Transmission - Power shuttle transmission internal components

Clutch - Disassemble Clutch B of Dual command (2 speed power shift) + Assemble T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Remove the circlip (1), the disk assembly and the anti--rotation pin.

Carry out the operations described for clutch A in points from 6 to 20 in Clutch - Disassemble Clutch A of Dual command (2 speed power shift) (21.154) to correctly disassemble / assemble the disks and the springs of the clutch B.

SEZ21CAP4A-49

SEZ21CAP3A-23

SEZ21CAP3A-54

Insert the pin into the space between the teeth of the metal disk keyed onto the clutch B bell housing, left free by the split in the springs.

Take great care over positioning the disk of clutch B. On one tooth it has a retaining pin (1), the position of this tooth must be very far from the space where the pin is inserted described in the preceding operation.

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Transmission - Power shuttle transmission internal components

WLAPL4S21C402A

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Transmission - Power shuttle transmission internal components

Clutch - Assemble Clutch A of Dual command (2 speed power shift) T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Replacing the seal on the clutch casing internal hub. 1.

Position the O--Ring seal (1) in the relative seat on the clutch casing internal hub.

SEZ21CAP4A-41

SEZ21CAP4A-42

SEZ21CAP4A-89

Position the external ring (1) of the seal on the guide on tool 380000290 (2).

Position the guide (2) on tool 380000290 on the clutch casing internal hub and push the ring (3) into position using the press (1) on tool 380000290.

Refit the clutch A

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Transmission - Power shuttle transmission internal components

Position the clutch casing A (1) under a press and, using tool 380000291 (2) and adapter, compress the Belleville springs and fit the spring stop ring.

SEZ21CAP4A-88

SEZ21CAP4A-43

SEZ21CAP4A-44

SEZ21CAP4A-91

Fit the casing (1) of the clutch A on its cover (2) and secure it with the circlip.

Assemble the clutch disk assembly on the clutch casing A as described here: - Insert the first metal disk (2) on the casing (1) of the clutch A.

On the casing (1) of the clutch A, make a reference mark (2) to time the splits of the springs during the assembly operation.

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Transmission - Power shuttle transmission internal components

10.

11.

12.

Do the timing of the swings (1) and splits (2) of the springs as shown in the figure.

SEZ21CAP4A-92

SEZ21CAP4A-45

Insert the first spring on the casing (1) of the clutch A, keeping the split of the spring (2) timed with the reference mark (3) made beforehand.

Insert the first clutch disk (2) on the casing (1) of the clutch A, centring the spring (3) previously mounted on the outer edge of the disk (2).

SEZ21CAP4A-46

SEZ21CAP4A-93

Insert the second metal disk (2) on the casing (1) of the clutch A.

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Transmission - Power shuttle transmission internal components

13.

14.

15.

Insert the second spring (3) on the casing (1) of the clutch A, keeping the split timed with the reference mark (2) made beforehand.

SEZ21CAP4A-94

SEZ21CAP4A-47

WLAPL4S21C401A

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Transmission - Power shuttle transmission internal components

16.

17.

Refit the unit (1) composed of: - forward gear clutch A bottom / reverse gear clutch driving hub B ( (14), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154)) - bearing ( (10), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154)) of clutch A driven hub ( (9), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154)) - circlip retaining bearing on the hub ( (11), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154)) - circlip retaining bearing on part (14) ( (13), Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154))

SEZ21CAP4A-48

SEZ21CAP4A-95

Fit the circlip (1) retaining the unit previously fitted inside the clutch A.

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Transmission - Power shuttle transmission internal components

Clutch - Disassemble Clutch casing with power shuttle and creeper unit T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

NOTE: In order to work on the reverser--creeper unit first detach the cab or platform and then remove the clutch casing as described in Clutch - Disassemble Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units (21.154) . Then proceed as follows: 1.

Fix the gearbox--transmission casing to the rotating stand 380000301 (1) using the brackets.

SEZ21CAP5A-12

SEZ21CAP5A-13

For disassembly of the Power Shuttle clutches, please refer to ( Clutch - Disassemble Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units (21.154) , Clutch - Assemble Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units (21.154) , Transmission drive and driven shafts Disassemble . Disassembly (21.154), Transmission drive and driven shafts - Assemble (21.154)) .

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Transmission - Power shuttle transmission internal components

Extract the spring pin (1) and retrieve the creeper unit engagement external lever (2).

Unscrew the screw (1), then retrieve the spring (2) and the poppet ball (3).

Remove the creeper unit status sensor ( (1), Creeper - Sectional view Creeper unit selector sleeve (21.160)).

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SEZ21CAP5B-1

SEZ21CAP5A-1

Transmission - Power shuttle transmission internal components

SEZ21CAP5F-6

Remove the bearing ( (1), 5) together with the thrust washer (7) Power shuttle transmission - Sectional view longitudinal Power Shuttle and creeper unit gearbox (21.112), take out the split ring ( (2), 5) then extract the shaft ( (3), 5) together with: sliding sleeve ( (4), 5), clevis ( (2), 3) and rod ( (3), 3).

Extract the fixed sleeve for direct gear engagement. ( (5), 5), retrieve the half--rings ( (6), 5).

Retrieve the bearing ( (7), 5), remove the split ring ( (8), 5) with the washer.

From the front of the casing, use a suitable punch to strike the shaft ( (9), 5), then from the back retrieve the secondary shaft together with the two idlers ( (10) and (11), 5) of the reverse and of the creeper unit and thrust washer.

10.

From the left--hand side of the clutch casing, remove the grub nut (1) retaining the shaft (2) of the reverser idler gear (3), then remove it all.

SEZ21CAP5A-2

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Transmission - Power shuttle transmission internal components

11.

Remove the creeper unit engagement internal lever ( (4), 3) and the secondary shaft bearing ( (15), 5).

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Transmission - Power shuttle transmission internal components

Clutch - Assemble Clutch casing with power shuttle and creeper unit T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

NOTE: For the correct orientation of the various parts, refer to the illustrations in fig. 4 Clutch - Disassemble Clutch casing with power shuttle and creeper unit (21.154) or Power shuttle transmission - Sectional view longitudinal Power Shuttle and creeper unit gearbox (21.112) and Creeper - Sectional view Creeper unit selector sleeve (21.160) . NOTE: Before refitting the casings, supports and covers clean and de--grease the mating surfaces and apply sealing compound -approx. 2 mm (0.08 in)in diameter- as shown in Clutch - Exploded view Sealing compound application diagram for clutch A cover of Power Shuttle transmission with creeper unit - 20X20 version (21.154). 1.

Respect the tightening torques prescribed in Power shuttle transmission - Torque Power Shuttle transmission with creeper unit - 20X20 version (21.112) .

Fit the secondary shaft bearing and the creeper unit engagement internal lever.

Fit the driving shaft unit (forward drive primary, reverse drive and reverser driving gear, with their rings and bearings).

Fit the reverse drive idler gear unit, locking it with the screw.

From the back, fit the secondary shaft together with the two idlers of the reverser and of the creeper unit and thrust washer and, from the front, secure it with the thrust washer and the split ring.

Refit the half--rings and refit the fixed sleeve for direct gear engagement.

Fit the input sleeve to the gearbox together with: sliding sleeve, clevis and rod, and secure it with the split ring.

Mount the transmission shaft lubrication cover and then screw on the retaining nuts.

Assemble and secure the lubrication manifold, complete with the transmission shaft lubrication line.

10.

Position clutch B on the shaft and secure with the circlip.

11.

Assemble and secure the cover and clutch A.

12.

Insert the oil drainage union.

13.

Re--fit the control valve.

14.

Refit the bearings inside the shafts and the thrust washer (7) Power shuttle transmission - Sectional view longitudinal Power Shuttle and creeper unit gearbox (21.112) on the upper shaft.

NOTE: As regards the: Driving shaft removal-installation Clutch (A) removal-installation Clutch (B) removal-installation please refer in order to Transmission drive and driven shafts - Disassemble (21.154), Transmission drive and driven shafts - Assemble (21.154), Clutch - Disassemble Clutch A. (21.154), Clutch - Assemble Clutch A (21.154), Clutch - Disassemble Clutch B (and assemble) (21.154) .

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Transmission - Power shuttle transmission internal components

Transmission drive and driven shafts - Disassemble T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

NOTE: For the correct orientation of the various parts, refer to Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. (21.154). To remove the gearbox, proceed as follows. 1.

Remove the circlips ( (1) and (2)).

Extract the reverse driving gear (3).

Take out the circlip (4).

Grip the forward gear shaft (6) from the back and tap on the reverse gear / shaft (5) on the back and extract it.

Remove the bearing (7) from the forward gear shaft.

Remove the circlip (8).

Remove the main shaft.

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Transmission - Power shuttle transmission internal components

Transmission drive and driven shafts - Assemble T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

DRIVING SHAFT NOTE: For the correct orientation of the various parts, refer to Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. (21.154). - Fit the circlip (8). - Mount the bearing (7) inserting it from the back of the forward gear shaft, make it flush against the ring. - Insert the forward gear shaft (6), from the front, into the reverse gear shaft (5), on the back, until the latter reaches the position reaching the bearing. - Insert the bearing retaining circlip (4) into the reverse shaft. - Insert the gear (3) from the back of the forward gear shaft, make it flush with the bearing. - Insert the circlips (2) and (1).

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Transmission - Power shuttle transmission internal components

Transmission drive and driven shafts - Disassemble . Disassembly T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Remove the circlips ( (1) and (2)).

Extract the reverse driving gear (3).

Take out the circlip (4).

Grip the forward gear shaft (6) from the back and tap on the reverse gear / shaft (5) on the back and extract it.

Remove the bearing (7) from the forward gear shaft.

Remove the circlip (8).

Remove the main shaft.

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Transmission - Power shuttle transmission internal components

Transmission drive and driven shafts - Assemble T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

DRIVING SHAFT - Dual command (2 speed power shift) NOTE: For the correct orientation of the various parts, refer to Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) (21.154). - Fit the circlip (8). - Mount the bearing (7) inserting it from the back of the forward gear shaft, make it flush against the ring. - Insert the forward gear shaft (6), from the front, into the reverse gear shaft (5), on the back, until the latter reaches the position reaching the bearing. - Insert the bearing retaining circlip (4) into the reverse shaft. - Insert the gear (3) from the back of the forward gear shaft, make it flush with the bearing. - Insert the circlips (2) and (1).

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Transmission - Power shuttle transmission internal components

Transmission drive and driven shafts - Disassemble T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

DRIVEN SHAFT - Dual command (2 speed power shift) 1.

Remove the reverse driven gear (1)/ gear (3) governing clutch C, together with the bearings and the thrust washer.

SEZ21CAP4A-32

SEZ21CAP4A-33

SEZ21CAP4A-34

Remove the clutch assembly (1) by extracting it from the driven shaft (2).

Remove the retaining ring (3), the clutch reaction disc (2) and extract the clutch discs (1). Repeat the operation on the other clutch.

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Transmission - Power shuttle transmission internal components

Position tool 380000243 (2) on the clutch body (1) and secure in a vice, then compress the spring by tightening nut (3).

SEZ21CAP4A-35

SEZ21CAP4A-36

SEZ21CAP4A-37

Remove the circlip (1) retaining the cup (2), unscrew the nut of tool 380000243 and remove the spring (3) together with the above--mentioned parts.

Remove piston (1) using a compressed air jet.

Repeat operations no. 5. and 6. on the opposite side and remove the snap ring, cup, spring and piston.

Next operation: Transmission drive and driven shafts - Assemble (21.154).

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Transmission - Power shuttle transmission internal components

Transmission drive and driven shafts - Assemble T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

DRIVEN SHAFT - Dual command (2 speed power shift) 1.

Check the wear on the various components, especially the seals, replacing if necessary.

Position the guide on tool 380000245 (1) on the clutch casing hub (3), fit the seal (2) and push it into its seat using the press of tool 380000245 (1).

Repeat the same operation for the seal on the hub on the opposite side too.

SEZ21CAP4A-38

NOTE: After having positioned the two seals (2) on the hubs, allow to settle in the seats for at least 15 minutes before fitting the clutch control pistons 4.

Refer to the illustrations in fig. Power shuttle transmission - Sectional view Longitudinal cross--sectional view of Power Shuttle with Dual Command (2 Speed Power Shift) function. (21.112) for the correct orientation of the various parts.

Using tool 380000243 perform operations no. 6. and 5. Transmission drive and driven shafts - Disassemble (21.154) on both sides.

Insert the clutch plates, reaction disk and circlip on both sides.

Insert the clutch output gear D in the clutch assembly, insert the toothed thrust washer on the driven shaft, then insert the clutch assembly onto the driven shaft.

Insert the thrust washer on the driven shaft, then insert the reverse driven gear / the gear governing the clutches C, together with the bearings on the driven shaft.

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Transmission - Power shuttle transmission internal components

Transmission drive and driven shafts - Adjust Gearbox driving shaft end float adjustment NOTE: When fitted, the driving shaft gears must have an end float of 0 - 0.25 mm (0.000 - 0.010 in). The bearings must be adjusted to avoid assembling the unit with axial preload. In order to carry out this adjustment, construct tool 50007 in a workshop. 1.

Assemble all driving shaft components on the workbench, replacing the two rear bearings and the adjusting ring with tool 50007 (1).

Insert a screwdriver between the gear and the relative bushing and measure the clearance (H) with a feeler gauge.

Measure the height (C) of the tool 50007 and the thickness of the internal rings of the two rear bearings ( (1) and (2)).

The required adjusting thickness will be given by: S = (H) + (C) - (A) - (B) where: (H) = measured clearance (A) and (B) = bearings measured thickness (C) = height of the tool. Example: - measured clearance (H) = 1.3 mm (0.051 in) - height of tool = 43.5 mm (1.713 in) - thickness of ball bearing (1) = 22.9 mm (0.902 in) - thickness of roller bearing (2) = 18 mm (0.709 in) - adjusting shim thickness: S = 1.3 mm (0.051 in) + 43.5 mm (1.713 in) - 22.9 mm (0.902 in) - 18 mm (0.709 in) = 3.9 mm (0.154 in).

SEZ27CAP1A-82

SEZ27CAP1A-83

NOTE: As the gears must be assembled with an axial clearance of 0 - 0.25 mm (0.000 - 0.010 in), a 3.75 mm (0.148 in) shim (S) must be assembled, providing axial clearance of: 3.9 mm (0.154 in) - 3.75 mm (0.148 in) = 0.15 mm (0.006 in).

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Index Transmission - 21 Power shuttle transmission internal components - 154 Clutch - Assemble Clutch A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Clutch - Assemble Clutch A of Dual command (2 speed power shift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Clutch - Assemble Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units . . . . . . . . 34 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Clutch - Assemble Clutch casing with power shuttle and creeper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Clutch - Assemble refit the clutch casing with power shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Clutch - Disassemble Clutch A of Dual command (2 speed power shift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Clutch - Disassemble Clutch A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Clutch - Disassemble Clutch B (and assemble) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Clutch - Disassemble Clutch B of Dual command (2 speed power shift) + Assemble . . . . . . . . . . . . . . . . . . . . . . . 37 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Clutch - Disassemble Clutch casing with Power Shuttle and Dual Command (2 Speed Power Shift) units . . . . . 27 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Clutch - Disassemble Clutch casing with power shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Clutch - Disassemble Clutch casing with power shuttle and creeper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Clutch - Exploded view Sealing compound application diagram for clutch A cover of Power Shuttle transmission with creeper unit - 20X20 version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Clutch - Hydraulic schema Power Shuttle transmission -- Clutch A at rest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Clutch - Hydraulic schema Power Shuttle transmission -- Clutch A engaged. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Clutch - Static description Clutch A at rest / engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Gears, shaft, and bearings - Static description Power Shuttle transmission with creeper unit -- 20X20 version . 10 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Transmission drive and driven shafts - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Transmission drive and driven shafts - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Transmission drive and driven shafts - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Transmission drive and driven shafts - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Transmission drive and driven shafts - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

Transmission drive and driven shafts - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Transmission drive and driven shafts - Disassemble . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft of Dual Command (2 Speed Power Shift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Transmission drive and driven shafts - Sectional view Longitudinal section of the main shaft. . . . . . . . . . . . . . . . . 11 T5.95 12 x 12 PS, T5.105 12 x 12 PS, T5.115 12 x 12 PS

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Transmission - 21 Gearbox internal components - 145

T5.105 T5.115 T5.95

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Contents Transmission - 21 Gearbox internal components - 145

FUNCTIONAL DATA Drive shaft Dampener - Sectional view Longitudinal section through flexible coupling. Power Shuttle unit . . . . . . . . 3

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Transmission - Gearbox internal components

Drive shaft Dampener - Sectional view Longitudinal section through flexible coupling. Power Shuttle unit

SEZ18CAP1B-3

1. Flywheel. 2. Flexible coupling. 3. Shuttle clutch driving shaft. 4. Engine / flywheel retaining bolts.

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Index Transmission - 21 Gearbox internal components - 145 Drive shaft Dampener - Sectional view Longitudinal section through flexible coupling. Power Shuttle unit . . . . . . 3

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Transmission - 21 Creeper - 160

T5.105 T5.115 T5.95

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Contents Transmission - 21 Creeper - 160

TECHNICAL DATA Creeper General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

FUNCTIONAL DATA Creeper Sectional view Creeper unit selector sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Creeper Adjust creeper coupling flexible cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Creeper hand lever Adjust creeper coupling flexible cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Transmission - Creeper

Creeper - General specification T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

CREEPER UNIT DATA Type Method of operation

Ordinary gear train with spur gears, located between main clutch and gearbox, in series with the two clutches of the reverser. Providing 20 forward gears and 20 reverse gears lever located on right--hand side of operator

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Transmission - Creeper

Creeper - Sectional view Creeper unit selector sleeve T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

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Transmission - Creeper

WLAPL4S21C502H

transmission Power Shuttle with creeper unit - (20X20 version)

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Transmission - Creeper

(A). Longitudinal cross--section of clutch casing on creeper unit engagement clevis (B). Cross--section of clutch casing on creeper unit engagement clevis (C). Vertical longitudinal view of clutch casing on creeper unit engagement clevis (a). End of creeper unit engagement clevis in position of reduction unit disengaged. (b). End of creeper unit engagement clevis in position of reduction unit engaged. (1). Creeper unit status sensor. (2). Creeper unit engagement clevis. (3). Creeper unit engagement rod. (4). Safety pawl operating surface. (5). Power shuttle control valve. (6). Creeper unit selector sleeve. (7). Gearbox input shaft / sleeve. (8). Forward gear shaft. (9). Power take--off shaft. (10). Spring pin. (11). Creeper unit selector external lever. (12). Spring pin. (13). Seal. (14). Creeper unit selector internal lever. (15). Rod for range engagement clevis. (16). Safety pawl, prevents engaging the reduction gear with the fast range engaged and it prevents engaging the fast range with the reduction gear engaged. (17). Rod trip unit positioning spring. (18). Poppet ball retaining screw. (19). Poppet ball. (20) . Transmission oil pressure sensor.

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Transmission - Creeper

Creeper - Static description T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Power Shuttle transmission with creeper unit -- 20X20 version The Power Shuttle - creeper unit is a device providing 20 forward gears and 20 reverse gears. The creeper unit only intervenes in slow and medium slow ranges, a mechanical interlock prevents creeper engagement in the fast ranges.

Creeper unit (see Power shuttle transmission - Sectional view longitudinal Power Shuttle and creeper unit gearbox (21.112)) The creeper unit is installed inside the clutch casing, after the two clutches of the reverser (Power Shuttle) and it is controlled by a special lever located on the right--hand side of the operator. The creeper unit is composed of a group of three spur gears: a sliding control gear.

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Transmission - Creeper

Creeper - Dynamic description Gearbox operation The tractor features many transmission ratios thanks to the combined use of different levers, so that for each main gear it is possible to obtain different speeds, within the framework of the same range, without using the clutch pedal. If for whatever reason there is the need to stop the tractor momentarily, press this control button and the tractor will stop immediately. Release the button to restart work.

WLAPL4S21C318A

WLAPL4S21C310A

WLAPL4S21C313A

Reactive switch On the left-hand upright there is a switch to select the reactivity of the electro-hydraulic shuttle. Depending on the position of the button there is a different response in the speed of inverting the direction of travel • Position (A) low reactivity • Position (B) high reactivity • Position (C) standard reactivity

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Transmission - Creeper

Transmission and range gear lever By means of the transmission lever (1) it is possible to select the four gear ratios (1, 2, 3, 4). By means of the range gear lever (2) it is possible to select the different ranges. • I slow; • II medium; • III fast To change from one range to another, always stop the tractor; to change from one gear to another, use the main shift lever after fully depressing the clutch pedal (the tractor does not have to be halted as the gears are synchroengaged). NOTE: By using the main shift lever (1) , range gear lever (2) and shuttle lever ( (3) , 1 ) you can select 12 forward gears and 12 reverse gears.

WLAPL4S21C315A

WLAPL4S21C314A

Creeper lever Another creeper unit control lever (4) allows you to select another 8 underdrive gears, in the medium and slow ranges, in both forward and reverse drive. To move the lever you need to pull the safety ring upwards (5) . • Move the lever forwards into position (A) to disengage the creeper unit (normal gears). • Move the lever backwards into position (B) to engage the creeper unit (underdrive). NOTE: Combined use of the controls of the gearbox ( (1) , 4 ), range gear ( (2) , 4), ( (3) , 1 ) with the creeper unit ( (4) , 5 ), reducing the medium and slow ranges adds another 8 gears, in all the combination enables selecting 20 forward gears and 20 reverse gears.

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Transmission - Creeper

Clutch pedal On the clutch pedal (1) there is a potentiometer (2) , which is like the clutch cable of a manual transmission; instead of transmitting the operator's actions through the flexible cable to the coupling of the mechanical clutch, it transmits electric pulses to the control unit. This receives a current of 5 V and a ground signal from the control unit, being a variable resistor, containing a slider, it sends a signal, to the control unit again, that varies according to the travel of the pedal. The operator, using the pedal, governs the control unit and with the speed of release - operation gives the clutch packing speed; with the pedal pressed it releases the clutches, vice versa with the pedal released it packs them obtaining the greatest traction. Again on the clutch pedal (1) there is also a switch, inside of which it has two contacts one normally open and one normally closed, this has a double function. - Switch normally closed with pedal released. It sends a current, coming from a fuse via the shuttle lever (with the lever in the rest position with the switch on), the control unit will use this current to feed the modulated solenoid valves that will send oil to the clutches. - Switch normally closed with pedal released. This is on the starting circuit between the key and the starting relay in series with the clutch of the power takeâ&#x2C6;&#x2019;off; with the pedal pressed it closes and allows starting. NOTE: To start the engine you need to put the shuttle and power takeâ&#x2C6;&#x2019;off ( PDF ) control levers into neutral, additionally you need to press the clutch pedal fully down.

WLAPL4S21C319A

WLAPL4S21C312A

WLAPL4S21C320A

Clutch pedal adjustment On the clutch pedal (1) there are two adjustments to make, a mechanical one that consists in completely screwing the plug (2) onto the specific support and the cap (3) onto the pedal. A second electrical adjustment is made on the switch, entering the diagnostic programs of the gearbox control unit RW , in H7 and at channel ch1 , the display will show the percentage of travel at which the contact, connected to the switch control unit, passes from a state of open to a state of closed (with the pedal released). If this switchover does not happen, on releasing the pedal, at the percentage of 11 - 13 % of the travel, use the adjuster (3) . NOTE: This adjustment is important because it affects the modulation of the clutches. The switch works in combination with the potentiometer: while the former supplies the current for the solenoid valves the latter, in a certain sense, provides their packing speed, by adjusting the pedal release time. If, for example, the switch closes at a much higher travel percentage there will be sharper modulation with the machine starting with a burst.

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Transmission - Creeper

Because of an incorrect maneuver by the operator, the display could show (CP) , forcing the operator to press the clutch pedal, in the following cases. A - Request for starting without pressing the clutch pedal with the operator not sitting in the seat, after 5 s so N ( shuttle lever in neutral) has been removed, the display shows (CP) requiring the operator to press the pedal to re-enable the clutch. B - If the operator leaves the seat for longer than one second the transmission is disabled, when requesting starting without the clutch pedal.

WLAPL4S21C311A

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Transmission - Creeper

Creeper - Adjust creeper coupling flexible cable. 1.

Move the lever (1) , in the cab, into the upright position (creeper unit switched off).

Move the lever (1) , on the gearbox in the creeper unit off position, fully forwards.

Move the fork of the flexible cable to a distance (L) = 155 mm (6.1024 in) from the reaction block, then secure the cable to the bracket.

Screw the fork in or out by half a turn at a time until you collimate the hole in the lever, and insert the pin.

Tighten the nut locking the fork.

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WLAPL4S21C501A

WLAPL4S21C502A

Transmission - Creeper

Creeper hand lever - Adjust creeper coupling flexible cable. 1.

Move the lever (1) , in the cab, into the upright position (creeper unit switched off).

Move the lever (1) , on the gearbox in the creeper unit off position, fully forwards.

Move the fork of the flexible cable to a distance (L) = 155 mm (6.1024 in) from the reaction block, then secure the cable to the bracket.

Screw the fork in or out by half a turn at a time until you collimate the hole in the lever, and insert the pin.

Tighten the nut locking the fork.

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WLAPL4S21C501A

WLAPL4S21C502A

Index Transmission - 21 Creeper - 160 Creeper - Adjust creeper coupling flexible cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Creeper - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Creeper - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Creeper - Sectional view Creeper unit selector sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Creeper - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 T5.95 20 x 20 (PS and Creeper), T5.105 20 x 20 (PS and Creeper), T5.115 20 x 20 (PS and Creeper)

Creeper hand lever - Adjust creeper coupling flexible cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Transmission - 21 Hi-Lo unit - 168

T5.105 T5.115 T5.95

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Contents Transmission - 21 Hi-Lo unit - 168

TECHNICAL DATA Hi-Lo unit General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

FUNCTIONAL DATA Hi-Lo unit Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Transmission - Hi-Lo unit

Hi-Lo unit - General specification T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

HI-LO unit Method of operation Number of driven plates in each HI-LO transmission clutch Driven disc thickness

provides two speeds ( HI= alta, LO= bassa) within the same gear. The two speeds can be engaged under load by means of two clutches in oil baths. by means of push--buttons located on the gear lever 5 1.75 - 1.85 mm (0.069 - 0.073 in) or 1.95 - 2.05 mm (0.077 - 0.081 in) steel 5 1.95 - 2.05 mm (0.077 - 0.081 in) N 401-4-20

Driven plate material Number of driving plates in each HI-LO clutch Drive disc thickness Driving plate material Thickness of clutch pack under a load of 1600 N (359.69 19.1 - 19.3 mm (0.752 - 0.760 in) (*) lb) 163,1 kg (*): Value to obtain by varying the thickness of the driving plates.

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Transmission - Hi-Lo unit

Hi-Lo unit - Static description T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Dual Command (2 Speed Power Shift) unit. The Dual Command (2 Speed Power Shift) is composed of two multi--disk clutches in an oil bath located on the driven shaft in the rear part of the clutch casing, and is controlled by the same control valve as the Power Shuttle. The Dual Command (2 Speed Power Shift) provides two speeds within the same gear. The two speeds ( HIGH or LOW) are selected by means of two push--buttons located on the gearshift lever. The HIGH speeds are commanded by the front clutch (C), whereas the LOW speeds are commanded by the rear clutch (D). The Dual Command (2 Speed Power Shift) provides 24 forward gears and 24 reverse gears. For a more thorough understanding of its operation, here we give the hydraulic diagrams and the relevant sequences.

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Transmission - Hi-Lo unit

Hi-Lo unit - Dynamic description Gearbox operation The tractor features many transmission ratios thanks to the combined use of different levers, so that for each main gear it is possible to obtain different speeds.

Transmission and range gear lever HI - LO version By means of the transmission lever (1) it is possible to select the four gear ratios (1, 2, 3, 4). By means of the range gear lever (2) it is possible to select the different ranges. • I slow; • II medium; • III fast To change from one range to another, always stop the tractor; to change from one gear to another, use the main shift lever after fully depressing the clutch pedal (the tractor does not have to be halted as the gears are synchroengaged). By using the main shift lever (1) , range gear lever (2) and shuttle lever ( (3) , 3 ) you can select 24 forward gears and 24 reverse gears.

WLAPL4S21C316A-

WLAPL4S21C317A-

Dual Command (2 Speed Power Shift) Gearbox The main shift lever (1) , equipped with two switches ( HI ) and ( LO ), supplies two speeds in the same gear ratio. (HI) — Fast gears (LO) — Low speed gears The button (2) , located on the front of the lever, is called the dump button and has the same function as the clutch pedal. By pressing the button it is possible to pass from one gear to another, within the framework of the same range, without using the clutch pedal. If for whatever reason there is the need to stop the tractor momentarily, press this control button and the tractor will stop immediately. Release the button to restart work.

With the HI range engaged, the green high gear range engaged indicator shown in the figure (hare symbol) lights up.

Electrohydraulic shuttle control lever “ Power Shuttle ” The shuttle lever (3) , on the left of the steering wheel, is used to select the direction of travel, forward or reverse. To select the direction of travel, move the lever upwards and forwards for forward movement or backwards for reverse. The selected direction of travel is highlighted on the central display (see 4 ) of the instrument panel with symbols. When released, the shuttle lever will return to the rest position, even if the engagement switch remains on. To select neutral, depress the button (A) on the end of the lever. To invert the direction of travel simply reduce the tractor speed down to the minimum, then use the lever.

WLAPL4S21C318A

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Transmission - Hi-Lo unit

A " (N) " symbol can be seen on the display in the case in which: A - Request for starting with operator not sitting in the driving seat, without using the clutch pedal. The display lasts for 5 s , it is removed first if the operator moves the lever into neutral using the button ((A) , 3 ) on the lever of the shuttle. A - Request for starting without using the clutch pedal, with the handbrake pulled up. For the first 5 s it displays a " P ", afterwards a " N " appears on the lever of the shuttle . This view forces the operator to put the lever of the shuttle into neutral by pressing the button ( A , 3). WLAPL4S21C310A

WLAPL4S21C313A

WLAPL4S21C319A

WLAPL4S21C312A

Clutch pedal On the clutch pedal (1) there is a potentiometer (2) , which is like the clutch cable of a manual transmission; instead of transmitting the operator's actions through the flexible cable to the couplings of the mechanical clutch, it transmits electric pulses to the control unit. This receives a current of 5 V and a ground signal from the control unit, being a variable resistor, containing a slider, it sends a signal, to the control unit again, that varies according to the travel of the pedal. The operator, using the pedal, governs the control unit and with the speed of release - operation gives the clutch packing speed; with the pedal pressed it releases the clutches, vice versa with the pedal released it packs them obtaining the greatest traction. Again on the clutch pedal (1) there is also a switch, inside of which it has two contacts one normally open and one normally closed, this has a double function. - Switch normally closed with pedal released. It sends a current, coming from a fuse via the shuttle lever (with the lever in the rest position with the switch on), the control unit will use this current to feed the modulated solenoid valves that will send oil to the clutches. - Switch normally closed with pedal released. This is on the starting circuit between the key and the starting relay in series with the clutch of the power take−off; with the pedal pressed it closes and allows starting. NOTE: To start the engine you need to put the shuttle and power take−off ( PDF ) control levers into neutral, additionally you need to press the clutch pedal fully down. 84568014 22/03/2013

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Transmission - Hi-Lo unit

WLAPL4S21C320A

WLAPL4S21C311A

Because of an incorrect maneuver by the operator, the display could show CP , forcing the operator to press the clutch pedal, in the following cases. (A) - Request for starting without pressing the clutch pedal with the operator not sitting in the seat, after 5 s so N ( shuttle lever in neutral) has been removed, the display shows CP requiring the operator to press the pedal to re-enable the clutch. (B) - If the operator leaves the seat for longer than one second the transmission is disabled, when requesting starting without the clutch pedal.

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Index Transmission - 21 Hi-Lo unit - 168 Hi-Lo unit - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hi-Lo unit - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

Hi-Lo unit - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T5.95 24x24 HiLo Trans., T5.105 24x24 HiLo Trans., T5.115 24x24 HiLo Trans.

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

84568014 22/03/2013 EN

SERVICE MANUAL Four-Wheel Drive (4WD) system

T5.105 T5.115 T5.95

84568014 22/03/2013

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

[23.202] Electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 T5.105 , T5.115 , T5.95

[23.304] Four-Wheel Drive (4WD) gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2 T5.105 , T5.115 , T5.95

[23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.3 T5.105 , T5.115 , T5.95

84568014 22/03/2013

Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202

T5.105 T5.115 T5.95

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Contents Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202

TECHNICAL DATA Electro-hydraulic control Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Command valve Dynamic description hydraulic diagram and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Front-Wheel Drive (FWD) Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Front-Wheel Drive (FWD) control valve Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Front-Wheel Drive (FWD) Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Front-Wheel Drive (FWD) control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DIAGNOSTIC Electro-hydraulic control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Electro-hydraulic control - Torque

MOIL12TR00588FA

Tightening torque Nm

kgm

M 12 x 1.5

M 12 x 1.25

4.5

M 12 x 1.25

2.5

M 12 x 1.25

M 18 x 1.50

M 8 x 12

1.5

PARTS TO BE TIGHTENED Thread Propeller shaft central support retaining bolt (C1) Parking brake control lever axial retaining bolt (C2) Screw with guide pin for brake disk braking sectors (C3) Drive gear housing retaining bolt (C4) Control cylinder oil delivery union (C5) Plug (C6) *

* : The plug requires a coating of LOCTITEÂŽ 270 prior to installation.

Electro-hydraulic control - Special tools 380000279: Guard for fitting the seal ( (28), Gearbox - Sectional view (23.304) ) 380000280: Guard for fitting the seal ( (27), Gearbox - Sectional view (23.304)) 380000285: Splining tool for fitting the seal (3) Gearbox - Sectional view (23.304). 50107: Adapter to make for drive gear spring disassembly--assembly.

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Electro-hydraulic control - General specification 4WD electro-hydraulic engagement NOTE: Refer to Front-Wheel Drive (FWD) - Sectional view (23.202) . Reduction ratio of drive gear device (on all models) Number of mobile friction sections (14) (one--sided) Number of mobile friction sections (14) (two--sided) Number of brake disks (12)

34/34 = 1:1 2 5 5

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Command valve - Dynamic description hydraulic diagram and operation Electro-hydraulically engaged/disengaged drive gear

SEZ23CAP1H-1

4WD gear engaged (upper image) 4WD gear disengaged (lower image) Circuit oil discharging Circuit oil under pressure

Operation Electro-hydraulically controlled four−wheel drive engagement is governed by the transmission ECU. When the four−wheel drive is engaged with the switch, a signal is sent to the control unit; this will cut off current to the solenoid valve and will mechanically engage front-wheel drive. The four−wheel drive is disengaged by turning off the switch on the control panel, the control unit will no longer receive any current. 84568014 22/03/2013

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

With the solenoid valve energized, oil is supplied to the mobile coupling internal chamber ( (19) , Gearbox - Sectional view (23.304) ) and the 4WD disengages. Lubrication is guaranteed by the oil in the rear transmission gearbox.

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) - Sectional view Sectional view of drive gear with electrohydraulic coupling

WLAPL4S23C101G

(1) . Driving shaft. (2) . Dust ring. (3) . Seal. (4) . Manifold ring. (5) . Circlip. (6) . Ball bearing. (7) . Coupling spring 4WD . (8) . Fixed engagement. (9) . Intermediate gear journal. (10) . Idler gear. (11) . Needle bearing. (12) . Parking brake discs.

(18) . (19) . (20) . (21) . (22) . (23) . (25) . (26) . (27) . (29) . (30) . (31) .

Driving gear. Mobile coupling. Plate. Circlip. Control cylinder oil delivery union. (24) . O-Ring seals. Metal seal rings Theoretical speed sensor. (28) . O-Ring seals. Lever axial retaining bolt (16) . Casing. Circlip.

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

(13) (14) (15) (16)

. . . .

Ball bearing. Braking sectors. Gasket OR . Parking brake control lever.

(17) . Thrust washer.

(32) . Front grooved sleeve. (33) . Clearance adjustment ring (L) . (34) . Circlip. (L) . Clearance = 1.2 - 1.7 mm (0.0472 - 0.0669 in) axial clearance of sleeve (32) . (M) . Gap = 0.75 mm (0.0295 in) . between parts (18) and (26) .

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) control valve - Sectional view Sectional views of the services spool valve with solenoid valves

SEZ31CAP2G-7

(A). Lever position with PTO synchronized with gearbox engaged. (B). Lever position with electrohydraulic PTO commanded by flywheel engaged. (1). 4WD disengagement solenoid valve. (2). Front or rear differential lock engagement solenoid valve. (3). Front or rear differential lock delivery union. (4). 4WD engagement delivery union. (5). Oil flow cut--off lever to solenoid valve (14), flywheel PTO clutch engagement, when engaged the PTO is synchronized with gearbox. 84568014 22/03/2013

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

(6). Cam to adjust valve stroke (11). (7). 4WD engagement delivery union. (10) External plug on outlet line. (11) Oil delivery to solenoid valve spool valve rod (14). (12) Bolt retaining valve (11). (13) Valve seal and dust seal (11). (14) Solenoid valve for oil flow to PTO clutch or clutch brake. (15) Clutch brake delivery fitting. (16) PTO clutch engagement cylinder delivery fitting. (17) Outlet line to transmission casing. (19) Solenoid valve support delivery fitting.

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) - Assemble drive gear components 1.

Check all parts and replace if worn.

Check the seals and replace, if necessary.

To position the O--rings ( (27) and (28), Gearbox Sectional view (23.304) ) in the seats on the driven shaft, use the specific tools: 380000280 (2) for the seal (3) and tool 380000279 for the seal (1).

Lubricate all parts.

Tighten the retaining bolts to the torque value indicated Electro-hydraulic control - Torque (23.202).

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) - Disassemble NOTE: With the drive gear casing on a workbench, proceed as follows: 1.

Using a punch, extract the circlip (2), pin (1) and remove the roller bearing, spacer, thrust washers and intermediate gear (3).

SEZ23CAP1A-36

SEZ23CAP1A-37

SEZ23CAP1A-38

SEZ23CAP1A-5

Unscrew the axial retaining screw (1) on the parking brake lever.

Using a wrench, extract the bolt (1) and remove the parking brake lever (2).

Using a screwdriver, remove the dust ring (1).

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Remove the oil seal (1).

SEZ23CAP1A-39

SEZ23CAP1A-40

SEZ23CAP1A-41

SEZ23CAP1A-6

Remove the 4WD drive gear disengagement oil delivery union (1).

Remove the oil delivery manifold ring (1) with a suitable punch.

Remove the circlip (1). Extract the shaft (2), complete with parts ( (6), (7), (19), (20) and (21), Gearbox - Sectional view (23.304) ); remove the parking brake disks ( (12) and (14)), the driven gear (18), fixed coupling (8) and thrust washer (17).

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Unscrew the two bolts (1) with relative brake sector guide pins and remove the brake sector and rear bearing.

SEZ23CAP1A-42

10.

11.

12.

Extract the parking brake shaft (2) and remove the O--ring (1) from the part (2).

SEZ23CAP1A-43

SEZ23CAP1A-44

SEZ23CAP1A-7

Position the driven shaft (1), previously removed in operation (8), in a hydraulic press, securing the bearing (2) in the clamps (3) as indicated in the drawing. Operate the press and extract the bearing (2).

Rotate the driven shaft through 180 Â°, position on the press as indicated in the drawing and, after having fitted an adapter 50107 (1) on the shaft, operate the press to compress the spring (4). Remove the snap ring (2), plate (3), spring (4) and mobile toothed coupling (5).

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) control valve - Remove To remove the services spool valve, proceed as follows: 1.

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

WLAPL4S10C101A

WLAPL4S10C108A

WLAPL4S10C110A

WLAPL4S10C109A

Set a container of suitable dimensions under the tank (tank capacity 140 l (37.0 US gal)). Drain the fuel tank by removing the bottom drain plug (1).

Set a mechanical stand under the left rear final drive. Take off the left rear wheel.

Unscrew the fixing bolts (1) and remove the left-hand steps (2).

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Remove the glove compartment. 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) , if fitted.

WLAPL4S10C111A

MOIL12APL0024AA

MOIL12APL0025AA

Detach the screws (1) of the rear fuel tank support (2), then detach the support itself.

Remove the eccentric nut (1) for adjusting the travel of the spool valve stem (2), remove the fork on the valve and detach the lever.

NOTE: The spool valve stem (1) hydraulically cuts off power take−off engagement commanded by the flywheel when the power take−off is synchronized with the gearbox. 8.

Detach the power take-off lubrication pipe (1), front differential lock pipe (2), rear differential lock (3), the feed to the services spool valve (4) and the four−wheel drive release pipe (5).

MOIL12APL0026AA

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Detach the electric connectors of the solenoids on the valve (1) , detach the hydraulic connection (2) with the fourâ&#x2C6;&#x2019;wheel drive casing, take out the nuts (3) fixing the spool valve to the transmission-gearbox casing, then, using suitable lifting equipment, remove the valve.

MOIL12APL0027AA

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) control valve - Install To refit the services spool valve, proceed as follows: 1.

Attach the spool valve to the gearbox casing with the bolts.

Connect the spool valve stem control lever 2 and adjust the spool valve stem with the eccentric nut so as to allow clearance between the valve 1 and the grub screw 3 at the travel limits: A) PTO synchronized with the gearbox. B) PTO electrohydraulically governed by the engaged flywheel.

MOIL12APL0028AA

Reconnect the wirings of the solenoids on the spool valve.

Reconnect the fourâ&#x2C6;&#x2019;wheel drive release pipe, the feed to the services spool valve, and the pipes of the front and rear differential lock.

Mount the rear fuel tank support.

Mount the fuel tank with the fixing bands, reinsert the drain plug, reconnect the pipes and refill with fuel.

Refit the left steps.

Fit the rear left-hand wheel and remove the chocks from under the wheels.

Connect the negative cable to the battery, put the battery cover back on again and lower the right-hand steps.

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Electro-hydraulic control - Troubleshooting Problem 4WD does not engage.

4WD remains engaged.

With electro-hydraulic 4WD disengaged, drive cannot be engaged by operating the brake pedals.

Possible Cause Drive gear engage/disengage switch faulty. Drive gear solenoid valve control jammed in delivery position. Spring ( (7), Gearbox - Sectional view (23.304) ) deformed. Transmission oil level low. Clogged oil filter. Hydraulic pump faulty. Drive gear engage/disengage switch faulty. Lack of power supply to the solenoid valve: connections loose or damaged, contact or faulty. Drive gear solenoid valve control jammed in discharge position. Oil leakage through the seals with consequent pressure drop: hub, piston or delivery union seals, or drive gear shaft seal rings. Brake pump pressure switch faulty.

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Correction Replace switch. Check solenoid valve. Replace if necessary. Overhaul the unit. 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 pressure switch.

Index Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202 Command valve - Dynamic description hydraulic diagram and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electro-hydraulic control - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electro-hydraulic control - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electro-hydraulic control - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electro-hydraulic control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Front-Wheel Drive (FWD) - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Front-Wheel Drive (FWD) - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Front-Wheel Drive (FWD) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Front-Wheel Drive (FWD) control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Front-Wheel Drive (FWD) control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Front-Wheel Drive (FWD) control valve - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304

T5.105 T5.115 T5.95

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Contents Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304

SERVICE Four-Wheel Drive (4WD) gearbox Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Remove Proceed as follows: 1.

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

WLAPL4S10C101A

MOIL12APL0078AA

MOIL12APL0079AA

MOIL12APL0080AA

Unscrew the front, central and rear bolts securing the drive shaft guard (1).

Take off the circlip (2) and extract the sleeve (1) from the front axle.

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.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

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.

WLAPL4S10C108A

WLAPL4S10C109A

WLAPL4S10C111A

MOIL12APL0024AA

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.

Remove the glove compartment. 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), if fitted.

Detach the screws (1) of the rear fuel tank support (2), then detach the support itself.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

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

WLAPL4S10C117A

10.

11.

12.

Detach the rev counter (1) from the Double Transmission casing.

MOIL12APL0084AA

MOIL12APL0082AA

MOIL12APL0083AA

Detach the delivery piping at the drive release (1) and the coupling between the services spool valve and the drive gear casing (2).

Detach the parking brake return spring (1). Remove the fixing pin (2) and detach the tie-rod (3) from the lever.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

13.

Position a hydraulic jack under the drive casing (1). Take out the bolts (2) securing the drive casing to the gearbox/transmission casing. Remove the drive gear casing.

MOIL12APL0081AA

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Install To refit the fourâ&#x2C6;&#x2019;wheel drive casing to the gearbox/transmission casing proceed as follows: 1.

Carefully clean the contact surfaces.

Apply a bead of approximately 2 mm (0.0787 in) of sealing compound on the transmission casing mating surface (see, Rear axle housing - Exploded view Sealing compound application diagram for transmission--gear box casing (27.100)) , with the aid of a hydraulic jack, fit the drive casing onto this, tightening the retaining bolts to the prescribed torque (see page 3) (see, Electro-hydraulic control - Torque (23.202)).

Refit the 4WD sensor, securing in position with the two retaining bolts.

Reconnect the hand brake tie-rod on the locking rod and make the adjustment as indicated (see, Parking brake external control - Adjust (33.110)).

Fit the coupling between the services spool valve and drive and the oil delivery piping to the drive release.

Fit the transmission oil drain plug back in position.

Refit the rear fuel tank support, refit the tank, connect the fuel pipes and tighten the fixing bands.

Refit the drive gear shaft sleeve on the drive gear casing grooved shaft, securing in position with a snap ring.

Fit the drive shaft guard back on.

10.

Fill the transmission/gearbox casing with oil (see, Consumables ()).

11.

Connect the battery negative lead.

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Index Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304 Four-Wheel Drive (4WD) gearbox - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Four-Wheel Drive (4WD) gearbox - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Four-Wheel Drive (4WD) system - 23 Drive shaft - 314

T5.105 T5.115 T5.95

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Contents Four-Wheel Drive (4WD) system - 23 Drive shaft - 314

TECHNICAL DATA Front drive shaft General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Four-Wheel Drive (4WD) system - Drive shaft

Front drive shaft - General specification Propeller shaft data NOTE: Refer to Gearbox - Sectional view (23.304) Thickness of rings (33) that adjust the position of the front sleeve (32) on the (4WD) propeller shaft Front sleeve end float (L)

1.5 mm (0.06 in) - 1.9 mm (0.07 in) - 2.2 mm (0.09 in) 2.5 mm (0.10 in) - 2.8 mm (0.11 in) - 3 mm (0.12 in) 3.3 mm (0.13 in) - 3.7 mm (0.15 in) - 4 mm (0.16 in) 4.3 mm (0.17 in) 1.2 - 1.7 mm (0.0472 - 0.0669 in)

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Index Four-Wheel Drive (4WD) system - 23 Drive shaft - 314 Front drive shaft - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

84568014 22/03/2013 EN

SERVICE MANUAL Front axle system

T5.105 T5.115 T5.95

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Contents Front axle system - 25

[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 T5.105 , T5.115 , T5.95

[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 T5.105 , T5.115 , T5.95

[25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3 T5.105 , T5.115 , T5.95

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Front axle system - 25 Powered front axle - 100

T5.105 T5.115 T5.95

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Axle support Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Four-Wheel Drive (4WD) axle Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SERVICE Four-Wheel Drive (4WD) axle Remove 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install 4 WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Assemble 4 WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Disassemble 4 WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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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

WLAPL4S25C102H

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Front axle system - Powered front axle

Front axle torque settings Thread

PARTS TO BE TIGHTENED Front axle support retaining bolt ( (C1), 1)

M18

1.5

Rear axle support retaining bolt ( (C2) , 1)

M18

1.5

Steering cylinder head locking ring nut ( (C3) , 1)

M22

1.5

Steering knuckle fixing on the piston ( (C4) , 1)

M22

1.5

Nut retaining steering ball joint on the stub axle ( (C5) , 1) M20

1.5

Steering cylinder retaining screws ( (C6) , 1 )

M18

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

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

Ring gear positioning ring nuts retaining grub screw ( (C17) , 2 *

M12 X 1.25

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. 84568014 22/03/2013

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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) 11 - 13.5 N·m (8.11 1.1 to 1.3 - 9.96 lb ft)

Front axle system - Powered front axle

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 - Sectional view

WLAPL4S25C104H

axle with brake and normal â&#x20AC;&#x201D; steering cylinder and bevel drive with hydraulic differential â&#x20AC;&#x201D; bevel drive with self-locking differential (Lim Slip) 84568014 22/03/2013

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Front axle system - Powered front axle

WLAPL4S25C105H

steering cylinder and bevel drive with hydraulic differential

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Front axle system - Powered front axle

WLAPL4S25C106H

bevel drive with self--locking differential ( Lim Slip )

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Front axle system - Powered front axle

(A) - Standard axle (without brakes). (B) - Axle with braking. (C) - Bolt fastening steering cylinder to axle. (D) - Fixing steering cylinder arm to stub axle. (E) - Differential unit with electro-hydraulic locking (F) - Self-locking differential unit ( Lim Slip ). (G) - Self-locking differential ( Lim Slip ). (a) . - 2.5 - 3 mm (0.0984 - 0.1181 in) â&#x2C6;&#x2019; Slide seal assembly stand-in (b) . - 1 mm (0.0394 in) â&#x2C6;&#x2019; Seal gap on axle shaft. (c) . - Seal assembly distance 11 mm (0.4331 in) . (d) . - Dust seal assembly distance 10 mm (0.3937 in) . (1) - Steering cylinder unit. (2) - Grub screw locknut. (3) . Axle shaft bush grub screw. (4) . Stub axle pin. (5) . Stub axle. (6) . Sunken seal. (7) . Wheel hub. (8) . Final drive ring gear support. (9) . Final drive ring gear. (10) . Final drive driven gears. (11) . Driven gear retaining thrust washer. (12) . Driven gear pin. (13) . (14) . (15) . (16) . (17) . (18) . (19) . (20) .

Thrust washer retaining screw. Needle bearing. Wheel hub cover. Ring nut retaining ring gear support to stub axle. Wheel hub cover retaining bolts. Wheel studs. Final drive ring gear unit support bearings. Seal.

(21) . Stub axle pin grease fitting. (22) . Stub axle rolling torque adjustment shims (23) . Axle shaft (24) . Brakes circuit. (25) . Axle shaft bearing carrier bushing. (26) . Seal. (27) . Axle shaft support bearing. (28) . Bearing retaining circlips. (29) . Front braking fitting. (30) . Cover of compartment for front brakes bleeder on wheel hub. (31) . Front brakes bleed screw. (32) . Front brake ring cylinder. (33) . Front brake ring piston. (34) . Disc brake support gear. (35) . Brake reaction disc. (36) . Brake reaction disc retaining circlip. (37) . Brake disc. (38) . Brake reaction disc. (39) . Circlip retaining ring gear to the carrier. (40) . Screws retaining ring gear support to stub axle. (41) . Steering cylinder end.

(43) . (44) . (45) . (46) . (47) . (48) . (49) . (50) .

Ball joint gasket. Steering cylinder. Bolt fastening steering cylinder. Pinion. Differential lock fitting. Front axle braking spool valve. Steering stop Differential lock cylinder / casing.

(51) . Differential lock piston. (52) . Differential lock piston O--ring. (53) . Front gear outer thrust washer. (54) . Differential lock front gear on right axle shaft. (55) . Front gear retaining circlip on the locking piston. (56) . Front gear inner thrust washer. (57) . Differential lock unit support. (58) . Differential lock hydraulic circuit fitting. (59) . Front gear retaining circlip on the differential cage. (60) . Front gear, differential cage side. (61) . Pinion bearing pre-load adjustment shim. (62) . Dust Seal. (63) . Seal. (64) . Differential unit retaining ring nut. (65) . Thrust washer preventing pinion ring nut from unscrewing. (66) . Rear axle support bushing. (67) . Rear axle support thrust washer. (68) . Pinion bearing pre-load adjustment spacer. (69) . Pinion support bearings. (70) . Crown wheel. (71) . Differential unit cage. (72) . Planet thrust washers. (73) . Planet and sun gear teeth clearance adjustment shims. (74) . Sun gear. (75) . Differential unit support bearings. (76) . Differential unit positioning ring nut. (77) . Ring nut retaining grub screw. (78) . Bearing support cap. (79) . Grub screw retaining pin 80. (80) . Planet gear journal retaining pin. (81) . Planet gear pin. (82) . Planet gears. (83) . Differential unit position adjustment shim. (84) . (85) . (86) . (87) . (88) . (89) . (90) . (91) . (92) . (93) . (94) .

Differential carrier right bearing retaining circlip. Differential lock cylinder / casing retaining screw. Metal disc keyed onto differential casing. Sun gear. Differential cage half shell retaining bolt. Planet gear pin. Planet gears. Differential cage. Pin retainer (89) . Friction disc keyed onto sun gear. Friction disc keyed onto sun gear.

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Front axle system - Powered front axle

(42) . Steering cylinder coupling.

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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 the 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.

Check the toe-in. 84568014 22/03/2013

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Disassemble 4 WD NOTE: Front axle overhaul operations must be carried out on the stand.

SEZ25CAP1A-13

SEZ25CAP1A-14

WLAPL4S25C115A

SEZ25CAP1A-16

Take out the three bolts (1) retaining the mudguard support (2).

Remove the plug and drain the oil from the axle casing.

Remove the plug (1) from the left--hand epicyclic final drive casing; repeat the same operation on the right-hand casing.

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Front axle system - Powered front axle

Remove the nuts (1) locking steering heads on stub axles.

Using an extractor, extract the steering heads from the seats on the stub axle housings.

Extract the steering heads governing the stub axles, on both sides.

SEZ25CAP1A-17

SEZ25CAP1A-18

WLAPL4S25C119A

WLAPL4S25C120A

Take out the power steering pipe bracket retaining bolt (1), remove the related unions and extract them. Remove the front axle rear support (2); remove the front support and washer.

Take out the four bolts retaining the steering cylinder (1) then remove it.

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Front axle system - Powered front axle

Take out the bolts (1) securing the left--hand final drive cover. Tighten two pins (2) and, using an extracting tool screwed into the oil drainage plug hole, remove the cover (1) .

WLAPL4S25C121A

10.

11.

12.

Remove the notching (1) on the ring nut (2) retaining the wheel hub bearings.

SEZ25CAP1A-25

SEZ25CAP1A-26

SEZ25CAP1A-27

Remove the lock nut on the wheel hub bearings using wrench 380000269 (1).

Remove the wheel hub (1) together with the epicyclic crown (2) and recover the disassembled parts.

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Front axle system - Powered front axle

13.

14.

15.

Take out the three upper pin retaining bolts (1) take out those of the lower pin and retrieve the shims.

SEZ25CAP1A-28

SEZ25CAP1A-29

SEZ25CAP1A-30

SEZ25CAP1A-31

Extract the upper pivot pin (1) as well as the lower one and remove the stub axle. Recover all disassembled parts.

Unscrew the locknut then take out the axle shaft support bushing retaining bolt.

16.

Using a crowbar, remove the axle shaft (1).

17.

To disassemble the right--hand final drive follow the operations carried out for left--hand final drive disassembly, from 9 to 17 .

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Front axle system - Powered front axle

18.

19.

20.

21.

Unscrew the two bevel drive-differential support retaining bolts from the axle casing, screw in two guide pins. Remove the remaining bolts and the bevel drive-differential support (1) , attach a chain and put the hoist under strain. Remove the bevel drive-differential support from the axle casing.

WLAPL4S25C129A

WLAPL4S25C130A

WLAPL4S25C131A

SEZ25CAP1A-36

Mount the unit in the vice. From the back of the differential unit, remove the propeller shaft thrust circlip, dust plate (1) and oil seal from the pinion stem.

Remove the rigid coupling for introducing oil into the differential lock (1).

Replace two screws of the differential lock actuator unit (select the ones diametrically opposite) with two screws at least 70 mm (2.76 in) long; set them at least 5 turns. Unscrew the others by a few turns alternately so as to allow stretching out the differential release spring, then remove both these and the two long ones. Remove the differential lock actuator unit.

NOTE: It is necessary to install two bolts with a minimum length of 70 mm (2.76 in) because the normal bell housing bolts are not long enough to allow the spring to extend to its full free length.

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Front axle system - Powered front axle

22.

23.

24.

25.

Using a screwdriver, remove the circlip (1) and the differential lock sleeve keyed onto the differential casing.

SEZ25CAP1A-37

SEZ25CAP1A-38

SEZ25CAP1A-39

SEZ25CAP1A-40

Using an Allen wrench remove the right ring nut lock screw (1); using pliers, remove the circlip on the left bearing support.

Take out the bolts (1) retaining the bevel crown wheel--differential support caps and remove them.

Remove the crown wheel--differential unit (1) from the casing, retrieve the races of the bearings and the right shim.

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Front axle system - Powered front axle

26.

Remove the securing ring on the pinion ring nut. Take off the ring nut with wrench 380000268 (1) keeping the bevel pinion shaft locked with wrench 380000257 (2). Remove the pinion together with the front bearing, rear bearing, bearing preload adjuster shim, spacer and the thrust washer preventing the ring nut from unscrewing.

SEZ25CAP1A-41

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Index Front axle system - 25 Powered front axle - 100 Axle support - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Four-Wheel Drive (4WD) axle - Assemble 4 WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Four-Wheel Drive (4WD) axle - Disassemble 4 WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Four-Wheel Drive (4WD) axle - Install 4 WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Four-Wheel Drive (4WD) axle - Remove 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Four-Wheel Drive (4WD) axle - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Powered front axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Powered front axle - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Powered front axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Front axle system - 25 Front bevel gear set and differential - 102

T5.105 T5.115 T5.95

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Contents Front axle system - 25 Front bevel gear set and differential - 102

TECHNICAL DATA Differential General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Limited slip differential General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Differential lock General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Limited slip differential Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Differential lock Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Bevel gear set and differential carrier Adjust Ring/Pinion Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Differential Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Limited slip differential Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Differential lock Multi-plate clutch - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

DIAGNOSTIC Differential lock Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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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 Thickness of bevel pinion bearing adjustment rings ( (0.138 in) - 3.55 mm (0.140 in) - 3.60 mm (0.142 in) (61) , Four-Wheel Drive (4WD) axle - Sectional view - 3.65 mm (0.144 in) - 3.70 mm (0.146 in) - 3.75 mm (25.102) figure 1) (0.148 in) - 3.80 mm (0.150 in) - 3.85 mm (0.152 in) 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) Thickness of sun pinion thrust washers ( (73) , 1.4 mm (0.055 in) - 1.5 mm (0.059 in) - 1.6 mm (0.063 Four-Wheel Drive (4WD) axle - Sectional view in) - 1.7 mm (0.067 in) - 1.8 mm (0.071 in) - 1.9 mm (25.102) figure 1) (0.075 in) - 2 mm (0.079 in)

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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 - 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 - 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

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

WLAPL4S25C107H

: Discharge oil : Pressurized oil 84568014 22/03/2013

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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

Bevel gear set and differential carrier - Adjust Pinion and crown wheel Adjusting the bevel crown wheel bearings and checking the clearance between the sides of the bevel drive teeth. 1.

Fit the differential unit on the differential bevel drive support together with the bevel drive complete with bearings ( (75), Four-Wheel Drive (4WD) axle - Sectional view (25.102) figure 1) and, on the right-hand side, bearing adjustment ring ( (83), Four-Wheel Drive (4WD) axle - Sectional view (25.102) figure 1) Sp , after measuring it.

SEZ25CAP1A-75

SEZ25CAP1A-76

SEZ25CAP1A-77

Install the differential casing support caps, tighten the relative bolts to a torque value of 59 - 108 N·m (43.52 - 79.66 lb ft) (6 to 11 kgm), then loosen and re-tighten to a torque of 20 N·m (14.75 lb ft) (2 kgm). Mount the adjuster shim ( (83) , Four-Wheel Drive (4WD) axle - Sectional view (25.102) figure 1) size 3 mm (0.1181 in) and the relevant retaining circlip on the right-hand side.

With the bearings perfectly lubricated, rotate the crown wheel and, at the same time, tighten the ring nut, on the left-hand side, using wrench 380000252 (1) to a torque value of 49 N·m (36.14 lb ft) (5 kgm) to take up the axial play between the components.

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Front axle system - Front bevel gear set and differential

Measure the backlash between pinion and crown wheel, using a 1/100 dial gauge (1) perpendicular to the outer edge of a tooth on the ring gear. Repeat the measurement in a further two positions 120 ° apart and calculate the average of the three values ( Gm ). Define the shim Sc to fit in place of the one of 3 mm (0.1181 in) , that is such as to produce a greater clearance between the teeth than the intended maximum. S = 3 - ( Gm X 1.34)

SEZ25CAP1A-78

SEZ25CAP1A-80

SEZ25CAP1A-76

Fit a shim ( (83), Four-Wheel Drive (4WD) axle Sectional view (25.102) figure 1) of the calculated thickness and with a 1/100 scale dial gauge (1) positioned perpendicular to the outside edge of one of the crown wheel teeth, check that the backlash between the pinion and the crown wheel is within the prescribed tolerance limits 0.15 - 0.20 mm (0.006 0.008 in).

Using wrench 380000257 adjust the ring nut and check, using torque wrench (1), that the rolling resistance torque of the crown wheel and pinion bearings, as measured in the same conditions used to check only the pinion, is: - A2 = A1 + 1 - 1.5 N·m (8.85 - 13.28 lb in) , where: A2 = pinion--crown wheel rolling resistance torque. A1 = rolling resistance torque of pinion only, as previously measured.

Tighten the cap retaining bolts to a torque of 113 N·m (1000.13 lb in).

Fit the safety plate, screwing the adjustment ring nut in or out, to reach the nearest notch.

Attach the bevel drive--differential to the axle casing after having carefully cleaned and degreased the mating surfaces and apply sealing compound (approx. 2 mm (0.08 in)) along the marked line shown in the drawing below.

NOTE: On Lim Slip version models measure the clearance between the teeth with the aid of the ring nuts, unscrewing one and screwing in the other, always recovering the clearance, to reach the prescribed value for the clearance: 0.15 - 0.20 mm (0.0059 - 0.0079 in)

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Front axle system - Front bevel gear set and differential

On reaching the prescribed clearance, use both ring nuts in an equal manner to reach the rolling resistance torque of the pinion - crown wheel: A2 = A1 + 1 - 1.5 NÂˇm (0.74 - 1.11 lb ft) (0.10 to 0.15 kgm)

Sealing compound application diagram for assembly of bevel drive unit and epicyclic final drive unit. 10.

The types of sealing compounds to be applied are specified in Basic instructions ().

SEZ25CAP1B-2

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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 LIM-SLIP unit

WLAPL4S25C102F

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--casings.

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), friction disk (11),metal disks (10) and the friction disks (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)

Description Metal disk Friction disk Friction disk

Quantity 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 Multi-plate clutch - Overhaul Front axle differential lock clutch assembly NOTE: Position the bevel crown wheel--differential assembly on the support 380000255 and proceed as follows: 1.

Remove the differential lock control internal pipe.

Remove the upper (2) and lower (1) bolts of the external differential lock bell housing and install two bolts (minimum length 70 mm (2.76 in)) in their place. Gradually unscrew the four remaining bell housing bolts so as to allow the gradual extension of the differential lock release spring.

SEZ25CAP1A-45

NOTE: It is necessary to install two bolts with a minimum length of 70 mm (2.76 in) because the normal bell housing bolts are not long enough to allow the spring to extend to its full free length. 3.

Unscrew the two 70 mm (2.76 in) bolts last of all, remove the bell (1), the spring (2) and differential lock control piston.

SEZ25CAP1A-46

SEZ25CAP1A-47

Using a screwdriver, remove the circlip (2) and the differential lock sleeve.

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Front axle system - Front bevel gear set and differential

Remove the circlip securing the differential lock piston, recover the sliding sleeve with the two thrust washers.

SEZ25CAP1A-48

SEZ25CAP1A-49

SEZ25CAP1A-50

Gently tap the piston out of the clutch bell housing.

Remove the differential lock piston.

To refit the differential lock clutch parts follow the disassembly procedure in reverse order, proceeding as follows.

Carefully check the condition of the two O--ring seals installed on the piston.

10.

Fit the clutch bell unit complete with spring and piston using the two 70 mm (2.76 in) bolts used during disassembly operations.

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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. With differential lock Switch governed by the brake pedal, conengaged, 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Bevel gear set and differential carrier - Adjust Ring/Pinion Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Differential - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Differential - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Differential lock - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Differential lock - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Differential lock - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Differential lock Multi-plate clutch - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Limited slip differential - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Limited slip differential - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Limited slip differential - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Limited slip differential - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

T5.105 T5.115 T5.95

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Contents Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

TECHNICAL DATA Planetary drive and hub General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Steering knuckle and king pin General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Planetary drive and hub Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Steering knuckle and king pin Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wheel hub Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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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 - 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 - 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

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-PURon 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). POSE GREASE

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

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. 84568014 22/03/2013

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Planetary drive and hub - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Planetary drive and hub - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Planetary drive and hub - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Planetary drive and hub - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering knuckle and king pin - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Steering knuckle and king pin - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel hub - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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

84568014 22/03/2013 EN

SERVICE MANUAL Rear axle system

T5.105 T5.115 T5.95

84568014 22/03/2013

Contents Rear axle system - 27

[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 T5.105 , T5.115 , T5.95

[27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 T5.105 , T5.115 , T5.95

[27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3 T5.105 , T5.115 , T5.95

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Rear axle system - 27 Powered rear axle - 100

T5.105 T5.115 T5.95

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Contents Rear axle system - 27 Powered rear axle - 100

TECHNICAL DATA Powered rear axle Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Rear axle system - Powered rear axle

Powered rear axle - Torque PARTS TO BE TIGHTENED Gearbox--transmission casing upper cover retaining bolts (C1) Bolts securing lift to rear transmission casing (C2) Nuts for stud bolts securing final drive casing to gearbox--transmission casing (C5) Drive wheel axle retaining bolt (C6) Gear driven shaft ring nut (C4) Gear driven shaft front bearing retaining bolt (C3) Guard retaining screw (C7)

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Tightening torque kgm Nm (lbft) 59 N·m (43.52 lb ft) 6 98 N·m (72.28 lb ft) 10 150 - 165 N·m (110.63 15,29 ÷ 16,82 121.70 lb ft) 250 N·m (184.39 lb ft) 25,5 280 - 309 N·m (206.52 28,5 ÷ 31,5 227.91 lb ft) 26 - 30 N·m (19.18 - 22.13 lb 2,65 ÷ 3,06 ft) 21 - 26 N·m (15.49 - 19.18 lb 2,14 ÷ 2,65 ft)

Rear axle system - Powered rear axle

WLAPL4S27C101H

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Rear axle system - Powered rear axle

Powered rear axle - Special tools 380000227: Clutch casing lift hook. 380000301: Rotating stand for overhaul operations. 380000249: Bevel pinion positioning gauge. 380000250: Tool for differential lock spring. 380000240: Universal hydraulic pressure control kit. 50041: Tool to be constructed for adjusting differential lock sleeve travel 50164: Tool to make for removal--installation of the final drive cover 50006: Punch to make for gearbox driving shaft disassembly. 50007: Tool to make for adjusting the gearbox driving shaft bearings. 50169: Tool to make for front axle reduction unit cover disassembly--assembly. 50144: Tool to make for bevel pinion extraction. 50027: Tool to make for adjusting the bevel drive.

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Index Rear axle system - 27 Powered rear axle - 100 Powered rear axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Powered rear axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Rear axle system - 27 Rear bevel gear set and differential - 106

T5.105 T5.115 T5.95

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Contents Rear axle system - 27 Rear bevel gear set and differential - 106

TECHNICAL DATA Bevel gear General specification Bevel drive and differential data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Bevel gear Adjust Tapered roller bearings adjustment for pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Differential Adjust Adjustment of the clearance between the sun and planet pinion teeth . . . . . . . . . . . . . . . . . . . . . . . 7

Differential lock hydraulic control Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

DIAGNOSTIC Rear bevel gear set and differential Troubleshooting Bevel drive and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Differential lock hydraulic control Troubleshooting Hydraulically controlled differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Rear axle system - Rear bevel gear set and differential

Bevel gear - General specification Bevel drive and differential data Bevel drive gear ratio: - All models

10/44 = 1:4.4

See adjustments ( Bevel gear - Adjust Adjustment of the bevel drive, checking clearance between the Clearance between sides of bevel drive gear teeth: (1) pinion / ring gear teeth and bearing pre-load. (27.106) - All models ) 0.18 - 0.23 mm (0.007 - 0.009 in) Type of differential with two side pinions controlled by the transmission ECU, governed with a Electro-hydraulically controlled differential lock switch on the back of the control panel to the right of the operator. See adjustment in Differential - Adjust Adjustment of Clearance between sides of sun and planet pinion teeth: the clearance between the sun and planet pinion teeth (27.106) - All models: 0.303 - 0.307 mm (0.012 - 0.012 in) See adjustment in Differential lock hydraulic control Differential lock sliding sleeve travel adjustments Adjust (27.106) - All models: 8.1 - 8.2 mm (0.319 - 0.323 in)

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Rear axle system - Rear bevel gear set and differential

Bevel gear - Adjust Tapered roller bearings adjustment for pinion shaft 1.

The bearing pre-load depends on the torque of the ring nut as there are no more spacers between the internal races of the bearings. Mount the external race of the bearing.

Assemble the bevel pinion and relative parts.

Tighten the adjusting nut (1), while simultaneously rotating the pinion shaft to ensure that the bearings are seated correctly, to a pinion rolling torque of 0.75 - 1.5 NÂˇm (6.64 - 13.28 lb in).

SEZ27CAP1A-89

SEZ27CAP1A-90

The prescribed rolling torque corresponds to a force measured with the dial torque (1) of 8.6 - 17.2 N (1.93 - 3.87 lb) (0,88 Ăˇ 1,75 kg) measuring it with the dial torque and cord wrapped around the slow gear installed on the pinion, ensuring that the gear shafts do not get driven.

NOTE: The pinion rolling torque can be read directly on the bevel crown wheel (not pre--loaded) using the values shown in Bevel gear - Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. (27.106) .

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Rear axle system - Rear bevel gear set and differential

Bevel gear - Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. 1.

With the bevel pinion fitted, insert the differential assembly complete with the bevel crown wheel. Fit the right--hand support (1) on the gearbox--transmission casing and position the ring nut (2) flush to the support.

Assemble the left-hand support and tighten, using wrench 50027 , the ring nut to a torque of 49 N·m (433.69 lb in) to bed the bearings.

Unscrew the left-hand ring nut, always keeping it in contact with the bearing.

Bring the left-hand ring nut into contact with the relative bearing and tighten to a torque of 9.8 N·m (86.74 lb in) to adjust the clearance.

Using a 1/100 dial gauge (1), measure the radial clearance on the sides of the bevel drive teeth (three measurements at 120 ° (120 °) and arithmetic mean of the three readings) and compare the average of the three values with the normal clearance: G = 0.18 - 0.23 mm (0.007 - 0.009 in), on average 0.21 mm (0.008 in) (the difference between the three measurements must not exceed 0.05 mm (0.002 in)).

Loosen the left-hand ring nut and tighten the right-hand one by the same amount to obtain the minimum clearance: G = 0.18 mm (0.007 in).

Using wrench 50027 (2), tighten the left--hand ring nut (1) to preload the bevel drive bearings.

The following table gives the relationship between the clearance between the teeth and the axial deviation needed to restore it.

0.05 0.19 0.15 0.29 0.25 0.39 0.35 0.49

mm mm mm mm mm mm mm mm

Clearance between the teeth (0.0020 in) (0.0075 in) (0.0059 in) (0.0114 in) (0.0098 in) (0.0154 in) (0.0138 in) (0.0193 in)

0.07 0.14 0.20 0.27 0.37 0.41 0.48 0.54

mm mm mm mm mm mm mm mm

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27.2 [27.106] / 5

(0.0028 (0.0055 (0.0079 (0.0106 (0.0146 (0.0161 (0.0189 (0.0213

Axial deviation in) in) in) in) in) in) in) in)

SEZ27CAP1A-91

SEZ27CAP1A-92

Rear axle system - Rear bevel gear set and differential

The rolling torque can be checked using torque wrench (1), according to the values shown on the table below.

SEZ27CAP1A-93

Pinion / ring gear 10/44 Measurement on the ring gear Pinion rolling torque (crp) Rolling torque of pinion + ring gear (crpc) 0.075 kgm (0.54 ftlbs.) 0.430 kgm (3.11 ftlbs.) ÷ 0.530 kgm (3.83 ftlbs.) 0.100 kgm (0.72 ftlbs.) 0.540 kgm (3.91 ftlbs.) ÷ 0.640 kgm (4.63 ftlbs.) 0.125 kgm (0.90 ftlbs.) 0.650 kgm (4.70 ftlbs.) ÷ 0.750 kgm (5.42 ftlbs.) 0.150 kgm (1.08 ftlbs.) 0.760 kgm (5.50 ftlbs.) ÷ 0.860 kgm (6.22 ftlbs.) NOTE: The value of the total rolling torque, measured on the ring gear, can also be obtained from: [(crp x44) : 10]+100 ÷ [(crp x44) : 10]+200 e.g.: [(0.075 x44) : 10]+100 ÷ [(0.075 x44) : 10]+200 = 0.430 kgm (3.11 ftlbs.) ÷ 0.530 kgm (3.83 ftlbs.) 10.

11.

Check the clearance between the teeth again, make three measurements 120° apart, calculate the mean and the result should be: G = 0.18 - 0.23 mm (0.007 - 0.009 in)

SEZ27CAP1A-92

SEZ27CAP1A-5

Lock the right and left--hand ring nuts in position with the lock ring (1).

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Rear axle system - Rear bevel gear set and differential

Differential - Adjust Adjustment of the clearance between the sun and planet pinion teeth NOTE: With the differential disassembled on the bench, proceed as follows. 1.

Fit the two sun gears ( (2) and (5)) without rings ( (1) and (6)) on the differential casing. Insert the planet gears ( (3) and (8)) complete with fifth wheel ring adjustment and pin (7); turn the retaining bolt (4) a few times to prevent the pin from sliding out.

SEZ27CAP1A-97

SEZ27CAP1A-96

SEZ27CAP1A-98

Manipulate the LH sun gear so that it comes into contact with the planet gear and, using a depth micrometer, measure the distance (H1), taking two diametrically opposed measurements, taking the arithmetic means of the two values measured.

Push the sun gear so that it touches the differential casing and measure the distance (H2).

Repeat the same operations on RH side gear.

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Rear axle system - Rear bevel gear set and differential

The axial movement of the sun gears ( (2) and (5)) without adjustment shims is given by: Gs or Gd = (H1) - (H2) where: Gs = axial movement of left ring gear ( LH); Gd = axial movement of right side gear ( RH); (H1) and (H2) = the left ( LH) or right ( RH) side gear measurements. The normal clearance envisaged between the sides of the side gear and differential pinion teeth is: 0.303 - 0.307 mm (0.012 - 0.012 in) arithmetic average 0.610 mm (0.024 in) for mods. 78/106 and 83/113 KW/HP. Therefore, the normal clearance and the equivalent axial movement of the sun gears has an average ratio of 1:1.7. The axial movement of the side gears corresponding to the normal clearance is: 0.610 mm (0.024 in) x 1.7 mm (0.067 in) = 1.04 mm (0.041 in) for mods. 78/106 and 83/113 KW/HP. Therefore the adjustment rings ( (1) and (6)) to insert on the differential housing will be given by: Ss = Gs - 1.04 mm (0.041 in) (for left side gear ( LH) on models 78/106 and 83/113 KW/HP). Sd = Gd - 1.04 mm (0.041 in) (for right side gear on models 78/106 and 83/113 KW/HP). Insert shims as close as possible to the value obtained.

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SEZ27CAP1A-97

Rear axle system - Rear bevel gear set and differential

Differential lock hydraulic control - Adjust Adjusting the position of differential lock engagement sleeve 1.

Assemble the differential lock release device (mechanically operated model) or the plate (version with hydraulic control) without the adjusting shim

Insert gauge 50041 ( (2), 2) with the 8.1 - 8.2 mm (0.319 - 0.323 in) shim between the sleeve and the differential housing, so that it makes contact with the sliding surfaces of the sleeve on the housing.

Using a crowbar, bring the sleeve into contact with gauge 50041 and the differential casing, adjusting the fork (1) to the position of the gauge.

SEZ27CAP1A-1

SEZ27CAP1A-2

SEZ27CAP1A-3

Using a feeler gauge (1), measure the clearance between the control pin (2) and the seat on the rod (3) (mechanically operated model).

Using a feeler gauge (1), measure the clearance between the plate (2) and the seat on the rod (3) (hydraulically operated model).

Position the required shim under the differential lock release control device (mechanically operated model) or under the plate (2) (hydraulically operated model) and secure in position using the bolts.

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Rear axle system - Rear bevel gear set and differential

Rear bevel gear set and differential - Troubleshooting Bevel drive and differential Problem Transmission is noisy while the tractor is moving, even when the gears are in neutral (not due to Final drives).

Transmission is noisy when tractor is under or released from load.

Possible Cause Correction Incorrect adjustment of bevel pinion and / Remove the rear transmission casing and correctly adjust the bevel crown wheel or bevel crown wheel bearings. and pinion support bearings (see Bevel gear - Adjust Tapered roller bearings adjustment for pinion shaft (27.106) and Bevel gear - Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. (27.106) and Differential - Adjust Adjustment of the clearance between the sun and planet pinion teeth (27.106) ). Incorrect adjustment or wear of sun and Remove the rear transmission casing, replace the worn parts and correctly adjust side pinions. the differential gears (see Bevel gear - Adjust Tapered roller bearings adjustment for pinion shaft (27.106) and Bevel gear - Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. (27.106) and Differential - Adjust Adjustment of the clearance between the sun and planet pinion teeth (27.106)). Excessive clearance between half--shaft Remove the rear transmission casing and replace the damaged parts. keyed groove and sun gears. Excessive coupling clearance between the Remove the rear transmission casing and teeth of the pinion and of the bevel crown correctly adjust the bevel crown wheel wheel. and pinion support bearings (see Bevel gear - Adjust Tapered roller bearings adjustment for pinion shaft (27.106) and Bevel gear - Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. (27.106) and Differential - Adjust Adjustment of the clearance between the sun and planet pinion teeth (27.106)). Remove the rear transmission casing, reInternal part faulty. place the worn parts and correctly adjust the differential gear clearance (see Bevel gear - Adjust Tapered roller bearings adjustment for pinion shaft (27.106) and Bevel gear - Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. (27.106) and Differential - Adjust Adjustment of the clearance between the sun and planet pinion teeth (27.106)).

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Rear axle system - Rear bevel gear set and differential

Problem Transmission noisy and assembly overheats.

Possible Cause Correction Pinion and / or bevel crown wheel support Remove the rear transmission casing and correctly adjust the bevel crown wheel bearing clearance insufficient. and pinion support bearings (see Bevel gear - Adjust Tapered roller bearings adjustment for pinion shaft (27.106) and Bevel gear - Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. (27.106) and Differential - Adjust Adjustment of the clearance between the sun and planet pinion teeth (27.106)). Insufficient coupling clearance between the Remove the rear transmission casing and teeth of the pinion and of the bevel crown correctly adjust the bevel crown wheel support bearings (see Bevel gear - Adjust wheel. Tapered roller bearings adjustment for pinion shaft (27.106) and Bevel gear Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. (27.106) and Differential - Adjust Adjustment of the clearance between the sun and planet pinion teeth (27.106)).

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Rear axle system - Rear bevel gear set and differential

Differential lock hydraulic control - Troubleshooting Hydraulically controlled differential lock 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: cylinder piston or feed pipe seals. 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: cylinder piston or feed pipe seals.

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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.

Index Rear axle system - 27 Rear bevel gear set and differential - 106 Bevel gear - Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bevel gear - Adjust Tapered roller bearings adjustment for pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bevel gear - General specification Bevel drive and differential data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Differential - Adjust Adjustment of the clearance between the sun and planet pinion teeth . . . . . . . . . . . . . . . . . . . . 7 Differential lock hydraulic control - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Differential lock hydraulic control - Troubleshooting Hydraulically controlled differential lock . . . . . . . . . . . . . . . . . 12 Rear bevel gear set and differential - Troubleshooting Bevel drive and differential . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Rear axle system - 27 Planetary and final drives - 120

T5.105 T5.115 T5.95

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Contents Rear axle system - 27 Planetary and final drives - 120

TECHNICAL DATA Planetary final drive General specification Transmission and range gear data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification Final drive data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Planetary final drive Sectional view rear transmission transverse sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Planetary final drive Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Final drive housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Driving wheel shaft Disassemble and assembly - drive wheel shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

DIAGNOSTIC Planetary final drive Troubleshooting Final drive fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Rear axle system - Planetary and final drives

Planetary final drive - General specification Transmission and range gear data 4 speed, constant--mesh, with synchronizers on all gears helical toothed cascade--type with 3 ranges. spur independent, by two hand levers located at the operator’s right side See adjustment in Transmission shaft - Adjust (21.140) 0 - 0.25 mm (0.000 - 0.010 in)

Transmission gearing type Reduction unit gearing type Gearbox and reduction unit controls Gearbox driving shaft end float: - all models

Planetary final drive - General specification Final drive data Type Reduction Ratio: − for rear wheels size 34 − for rear wheels size 38 Thickness of side gears thrust washers

epicyclic with three side pinions with straight toothing

Adjusting end float of side pinion casing axle shaft end float

Thickness of end float adjuster rings for side pinion casing

13 : (13+65) = 1 : 6 12 : (12+663) = 1 : 6.25 1 mm (0.0394 in) See adjustment in Driving wheel shaft - Disassemble and assembly - drive wheel shaft (27.120) − 0.2 - 0.4 mm (0.0079 - 0.0157 in) 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 (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 final drive - Sectional view rear transmission transverse sections

WLAPL4S27C105H

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Rear axle system - Planetary and final drives

(1) . Left bearing pre-load ring nut safety washer. (2) . Left bearing pre-load ring nut. (3) . Left differential bearing support. (4) . Left bearing. (5) - Differential lock sliding sleeve. (6) . Side gear. (7) . Right bearing. (8) . Right differential bearing support. (9) . Right bearing pre-load ring nut. (10) . Right bearing pre-load ring nut safety washer. (11) . Roller bearing. (12) . Epicyclic final drive pinion. (13) . Pinion pin. (14) . Plug. (15) . Drive wheel axle external gasket. (16) . Axle support bearing.

(17) . Drive wheel axle. (18) . Internal gasket. (19) . Axle support bearing. (20) . Epicyclic final drive support. (21) . Axle shaft (22) . Ring gear. (23) . Rear brake assembly. (24) . Brake piston. (25) . Brake disc. (26) . Wear disk. (27) . Differential (planet gears, planet gear journal, sun gears and casing). (28) . Ring gear. (29) - Differential unit guard (prevents the oil, moved by the differential in motion, from emulsifying). (30) . Bearing pre-load ring nut safety washer retaining bolt. (31) . Bearing support retaining bolt.

* - On refitting the wheel axle (at the time of replacement) fill the indicated areas with grease

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Rear axle system - Planetary and final drives

Planetary final drive - Disassemble Epicyclic final drive NOTE: With the assembly detached from the housing, proceed as follows. 1.

Remove the retaining ring (1).

Extract the pins and remove the gears, complete with the roller bearings.

SEZ27CAP1A-104

Refit all epicyclic final drive parts by inverting operations 1 and 2.

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Rear axle system - Planetary and final drives

Final drive housing - Remove 1.

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.

Lock the front wheels using chocks.

Detach the vertical tie--rod (1) and the LH anti--swing rod (2).

WLAPL4S10C101A

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.

10.

MOIL12APL0039AA

WLAPL4S10C117A

MOIL12APL0037AA

MOIL12APL0040AA

Position a stand (1) under the rear part of the fuel tank.

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 - Install 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 (0.0787 in) in diameter, as shown in figure Hydraulic service brakes - Exploded view Diagram of seal compound application for brake assembly and final drives on the transmission casing. (27.120)

Fit the final drive assembly using suitable equipment for lifting and retaining.

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.

Assemble the rear LH wheel.

Remove the column from under the tank and the fixed stand under the flex bar support. Lower the machine.

Fit the stabilizer strut and the vertical rod.

Remove the wedges from under the front wheels.

Connect the battery negative cable, put the battery cover back on and lower the right-hand steps.

10.

Fill the gearbox-transmission casing with oil: the prescribed product and the relevant quantity are given in section Consumables ().

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Rear axle system - Planetary and final drives

Driving wheel shaft - Disassemble and assembly - drive wheel shaft NOTE: With the final drive casing removed from the rear transmission, proceed as follows. 1.

Position the final drive casing (1) on a rotating stand.

SEZ27CAP1A-105

SEZ27CAP1A-106

SEZ27CAP1A-107

SEZ27CAP1A-108

Take out the bolt (1) securing the driven gear support on the drive wheel shaft and remove the safety plate.

Extract the support (1) from the driven gears and remove the end float adjuster shim from the support.

Using an adequate puller, extract the drive wheel shaft (1) and remove the rear bearing.

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Rear axle system - Planetary and final drives

Remove the front (1) and rear seal, then take out the front bearing and remove the grease plug..

To refit the final drive casing, proceed as follows. - For the correct orientation of the various parts, observe the illustrations in ( Transmission/Rear drive internal components - Sectional view (21.148) , Planetary final drive - Sectional view rear transmission transverse sections (27.120) . - Respect the tightening torques listed in Powered rear axle - Torque (27.100) . - Fit the rear seal using a suitable drift. - Use plenty of grease to lubricate the front part behind the seat of the bearing ( (16) , Transmission internal controls - Sectional view gear and range engagement devices (21.148) ). - Fit the front bearing and the relevant seal with an adequate drift. - Fill the gap between the bearing and seal with grease. - Assemble the drive wheel shaft. - Fit the driven gear support and the relative adjuster shim. - Insert the safety plate and tighten the bolt to the prescribed torque.. - Adjust the end float of the gear support as follows. - Install the grease plug.

SEZ27CAP1A-109

SEZ27CAP1A-110

Using a dial gauge (1), check that the end float of the support (2) is 0.2 - 0.4 mm (0.008 - 0.016 in); if not, adjust the shim .

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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 - Disassemble and assembly - drive wheel shaft (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 - Disassemble and assembly - drive wheel shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Final drive housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Final drive housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Planetary final drive - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Planetary final drive - General specification Final drive data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Planetary final drive - General specification Transmission and range gear data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Planetary final drive - Sectional view rear transmission transverse sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Planetary final drive - Troubleshooting Final drive fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

84568014 22/03/2013 EN

SERVICE MANUAL Power Take-Off (PTO)

T5.105 T5.115 T5.95

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Contents Power Take-Off (PTO) - 31

[31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 T5.105 , T5.115 , T5.95

[31.116] Three-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 T5.105 , T5.115 , T5.95

[31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 T5.105 , T5.115 , T5.95

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Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104

T5.105 T5.115 T5.95

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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 T5.95 NA, T5.105 NA, T5.115 NA

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Rear electro-hydraulic control Static description and operation of the spool valve of the electro-hydraulically engaged PTO . . . . . . . . . 5 Dynamic description and operation with independent PTO or synchronized with the gearbox . . . . . . . . . 9 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Power Take-Off (PTO) control valve Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic schema Hydraulic diagram with solenoid valve (de-energized) . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic schema Hydraulic diagram with solenoid valve (energized). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Dynamic description and services spool valve with rod (4) in PTO synchronized with gearbox position hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SERVICE Power Take-Off (PTO) speed rate selector Adjust PTO gearbox flexible stay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Synchronized Power Take-Off (PTO) controls Adjust synchronized PTO cable flexible stay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

DIAGNOSTIC Rear electro-hydraulic control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - General specification ELECTRO-HYDRAULICALLY ENGAGED PTO DATA 540/540E/1000 rev/min Power Take-Off Variations 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 revolution speed with engine at max. power 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 driven shaft at grooved terminal: - 540 RPM - 540E RPM - 1000 RPM 540/1000 rpm PTO Basic equipment Type Engagement and Control Direction of rotation (from tractor rear) Speed Selection Engine speed with PTO at a speed of 540 r.p.m. Engine speed with PTO at a speed of 1000 r.p.m.

65/88, 72/97 e 77/105 KW/CV 1. independent in relation to tractor speed or 2. synchronized with gearbox 1.. Electro-hydraulic. Gearbox governed by a lever on the left of the driver seat 2. mechanical by a hand lever on the left of the driver seat clockwise by means of hand lever located on the rear LH side of the driverâ&#x20AC;&#x2122;s seat 1938 RPM 1535 RPM 1926 RPM 641 RPM 809 RPM 1194 RPM 8,2 revolutions for one wheel revolution 11,7 revolutions for one wheel revolution 14,7 revolutions for one 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) 65/88, 72/97 and 77/105 KW/HP independent with respect to tractor speed Electro-hydraulic. Gearbox governed by a lever on the left of the driver seat. clockwise by means of hand lever located on the rear RH side of the driver's seat 1938 1926

Rear electro-hydraulic control - General specification T5.95 NA, T5.105 NA, T5.115 NA

ELECTROHYDRAULIC POWER TAKE--OFF - NORTH AMERICA version PTO 540/1000 RPM Type Engagement and Control Direction of rotation (from tractor rear) Speed Selection

65/88, 72/97 e 77/105 KW/CV independent with respect to tractor speed electrohydraulic by means of knob clockwise Activated, by means of an internal mechanical device, replacing the splined output shaft (see Output shaft Replace PTO splined output shaft and engagement modulation selection (31.114) ) 84568014 22/03/2013

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Power Take-Off (PTO) - Rear electro-hydraulic control

Engine speed with PTO at 540 RPM Engine speed with PTO at 1000 RPM PTO revolution speed with engine at max. power of 2300 RPM: - for PTO 540 RPM - for 1000 RPM PTO Diameter of driven shaft at grooved terminal: - 540 RPM - 1000 RPM

1938 RPM 1926 RPM 641 RPM 1194 RPM 34.925 mm (1.375 in) (6 splines) 34.925 mm (1.375 in) (21 splines)

Rear electro-hydraulic control - Special tools 380000227: Hook for lifting the power take--off. 380000243: Press for clutch spring. 380000258: Handgrip (with 50135).

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Static description and operation of the spool valve of the electro-hydraulically engaged PTO Moving the synchronized PTO engagement lever fully downwards, disengaged, makes the control levers act also on the rod of the spool valve (4), that takes on the position shown below. With the rod (4) in this position and the solenoid valve (1) deactivated, the spool valve hydraulic diagram is as shown in the figure below. The line (11) receives pressurized oil from the pump and the control valve (4) directs the pressurized oil to the solenoid control valve (1). With the solenoid valve (1) deactivated, the delivery line to the PTO clutch engagement cylinder (2) discharges and is connected to line (10), whereas the delivery line to the clutch brake (3) remains pressurized. Under these conditions the PTO clutch is disengaged and the clutch brake is engaged.

The hydraulic diagram shown in Power Take-Off (PTO) control valve - Hydraulic schema Hydraulic diagram with solenoid valve (de-energized) (31.104)illustrates this phase. In this phase the delivery line ( (7), Power Take-Off (PTO) control valve - Hydraulic schema Hydraulic diagram with solenoid valve (de-energized) (31.104)) discharges, whilst the lubrication valve (8), assumes the position shown in Power Take-Off (PTO) control valve - Hydraulic schema Hydraulic diagram with solenoid valve (de-energized) (31.104) thereby only lubricating the clutch rear bearing (3). The oil under pressure from line (11) can moreover be used for the services of lines (8) and (9). The figure shows solenoid valves (5) and (6) deactivated. With solenoid valve (5) deactivated, the delivery line (9) discharges and the 4WD engages. With solenoid valve (6) deactivated the delivery line (8) discharges, with the relative disengagement of the front and rear differential lock.

SEZ31CAP2F-3

services spool valve hydraulic diagram : Pressurised oil : Discharge oil (1) . Oil delivery solenoid valve to PTO clutch or clutch brake (deactivated). (2) . Delivery line (discharging) to the PTO clutch engagement cylinder.

(7) . Spool valve support. (8) . Delivery lines discharging (front and rear differential disengaged).

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Power Take-Off (PTO) - Rear electro-hydraulic control

(3) . Delivery line (pressurized) to the clutch brake. (4) . Rod of the spool valve (5) . 4WD disengagement solenoid valve.

(9) . Delivery line discharging (fourâ&#x2C6;&#x2019;wheel drive engaged). (10) . Outlet line to transmission casing. (11) . Delivery line from the pump to the services spool valve (7) .

(6) . Front or rear differential engagement solenoid valve.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Again with the synchronized PTO engagement lever fully downwards, disengaged, and solenoid valve ( (1) , 2 ) excited, the hydraulic diagram of the spool valve is as illustrated 2 . The line (11) receives pressurized oil from the pump and the spool valve (4) directs the pressurized oil to the spool valve of the solenoid valve (1). With the solenoid valve (1) activated, the delivery line to the PTO clutch engagement cylinder (2) is pressurized, whilst the delivery line to clutch brake (3) discharges and is connected to line (10) . The PTO clutch is therefore engaged and the clutch brake is disengaged. The hydraulic diagram shown in Power Take-Off (PTO) control valve - Hydraulic schema Hydraulic diagram with solenoid valve (energized). (31.104), illustrates this hydraulic phase. In this phase the delivery

line ( (7) , Power Take-Off (PTO) control valve Hydraulic schema Hydraulic diagram with solenoid valve (energized). (31.104)) is pressurized, so the lubrication control valve (8) takes on the position shown in the figure, permitting lubrication of the clutch front/rear bearings and the clutch. The oil under pressure from line (11) can moreover be used for the services of lines (8) and (9) . The figure shows solenoid valve (5) and (6) excited. With the solenoid valve (5) excited, the delivery line (9) is pressurized and the fourâ&#x2C6;&#x2019;wheel drive is disengaged. With the solenoid valve (6) excited, the delivery line (8) is pressurized and the front and rear differential lock is engaged.

SEZ31CAP2F-4

: Pressurised oil : Discharge oil (1). Oil delivery solenoid valve to PTO clutch or clutch brake (energized). (2). Delivery line (pressurized) to the PTO clutch engagement cylinder. (3). Delivery line (discharging) to the clutch brake. (4). Spool valve rod position (4) when the lever ( (1), figure 2 Rear electro-hydraulic control - Dynamic description and operation with independent PTO or synchronized with the gearbox (31.104)) is in position (E).

(7). Control valve support. (8). Pressurized delivery lines (front and rear differential engaged). (9). Delivery line pressurized ( 4WD disengaged). (10). Outlet line to transmission casing.

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Power Take-Off (PTO) - Rear electro-hydraulic control

(5). 4WD disengagement solenoid valve.

(11). Delivery line from the pump to the services spool valve (7)

(6). Front or rear differential engagement solenoid valve.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Dynamic description and operation with independent PTO or synchronized with the gearbox Independent PTO, operated by the engine In these conditions, operation is totally independent of the tractor ground speed, the speed of the power take−off depends directly on the engine RPM and not on the gearbox, you can therefore: • stop the tractor without stopping the power take--off; • stop the power take--off without stopping the tractor (by disengaging the power take--off clutch). The shaft rotates clockwise, as seen from behind the tractor. To operate the power take−off, proceed as follows: • Check that the yellow knob (1) 1 is pressed, that is in the power take−off disengaged position. • Move the selector lever (3) 2 from the neutral position ( N ) into the position corresponding to the desired speed; NOTE: To move the lever, you need to pull the stop collar upwards (4) .

WLAPL4S31C202A

WLAPL4S31C203A

After a few moments, press the yellow knob (1) and lift the collar (2) 1 together with the button to engage the power take-off. To disengage the power take-off clutch, just press the yellow button (1). NOTE: The power take-off disengages automatically when the engine is switched off. NOTE: Before selecting the power take−off speed, ensure you have fitted the correct splined output shaft for the speed you want to select.

PTO synchronised with gears The speed of the PTO synchronized with the gearbox depends directly on the rotation of the rear wheels and not on the engine speed. In this case, the power take-off receives power directly from the transmission. When the tractor is stationary, the synchronized PTO does not rotate. Reverse the direction of rotation of the output shaft by moving from forward gear to reverse. To operate the power take−off, proceed as follows:

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Power Take-Off (PTO) - Rear electro-hydraulic control

• • Check that the yellow knob (1) 3 is pressed, that is in the power take−off disengaged position. • Move the selector lever (3) 4 from the neutral position ( N ) into the position corresponding to the desired speed. NOTE: To move the lever, you need to pull the stop collar upwards (4) .

WLAPL4S31C202A

WLAPL4S31C203A

WLAPL4S31C204A

WLAPL4S31C208A

After a few moments, move the lever (5) 5 from the disengaged position (B) upwards into the engaged position (A). In this case, the power take-off receives power directly from the transmission. When stopping the machine, the power take−off does not turn, and when restarting it begins to turn again. To disengage the power take−off, stop the machine, move the lever (5) downwards, disengaged position (B) , and the speed selection lever into the neutral position ( N )

NOTE: With the lever (5) 5 in position (B) the power take−off works as described in the chapter on the independent power take−off, controlled by the engine. NOTE: Before selecting the power take−off speed, ensure you have fitted the correct splined output shaft for the speed you want to select. NOTE: Move the PTO operation selection lever ( (5), 5 ) onto (B) engaging sleeve ( (2), 6 ) on the gearbox gearing teeth (1) (PTO synchronized with gearbox).

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Hydraulic schema Tractor hydraulic diagram

WLAPL4S21C305F

(1). (2). (3). (4). (5). (6). (7). (8). (9).

Heat exchanger. Steering pump. Steering cylinders. Low pressure switch. Front differential lock. Power steering control valve. Power take--off solenoid valve. Differential lock solenoid valve. 4WD circuit.

(10). (11). (12). (13). (14). (15). (16). (17).

PTO brake. Electro-hydraulic PTO unit. Rear differential lock. User control valve. Four wheel drive release solenoid valve. Gearbox hydraulic control valve. Oil filter on delivery. Oil filter on suction.

Description of operation -- Hydraulic system Principle of operation of the hydraulic system The pump (2) draws oil from the rear transmission through the line, the oil is filtered through filter (17) and directed through the line to the power steering (6). After having served the power steering, the oil is directed through the filter (16), to control valve (15) of the transmission unit, and from here to the services control valve (13) and heat exchanger (1) in order to lower the temperature, afterwards the oil goes to provide lubrication. The services spool valve (13) whose operation is described in ( Rear electro-hydraulic control - Static description and operation of the spool valve of the electro-hydraulically engaged PTO (31.104) and Power Take-Off (PTO) control valve - Dynamic description and services spool valve with rod (4) in PTO synchronized with gearbox position hydraulic diagram (31.104) ) performs the following functions: - controlling the clutch brake cylinder (10); - controlling the PTO clutch engagement cylinder (11); - lubricating the clutch bearings and the PTO engagement clutch; - controlling the front and rear differential lock engagement (5) and (12); - disengaging four-wheel drive. 84568014 22/03/2013

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) control valve - Sectional view Sectional views of the services spool valve with solenoid valves

SEZ31CAP2G-7

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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 - Hydraulic schema Hydraulic diagram with solenoid valve (de-energized)

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Power Take-Off (PTO) - Rear electro-hydraulic control

WLAPL4S31C201J

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Power Take-Off (PTO) - Rear electro-hydraulic control

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Power Take-Off (PTO) - Rear electro-hydraulic control

: Discharge oil (1). Clutch brake cylinder with line (4) pressurized. (2). PTO clutch engagement cylinder (3) with line (7) discharging. (3). PTO clutch.

(6). Position of accumulator cylinder for gradual PTO engagement with line (7) discharging. (7). Discharging pump delivery line.

(8). Position of lubrication valve (8) with line (7) discharging (only lubricates rear bearing. (4). Delivery line to pressurized clutch brake cylinder. (9). Lubrication line (5) external union. (5). Lubrication line with valve (8) for lubrication of clutch (10). Plug. rear bearing only.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) control valve - Hydraulic schema Hydraulic diagram with solenoid valve (energized).

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Power Take-Off (PTO) - Rear electro-hydraulic control

WLAPL4S31C202J

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Power Take-Off (PTO) - Rear electro-hydraulic control

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Power Take-Off (PTO) - Rear electro-hydraulic control

: Discharge oil (1). Clutch brake cylinder with line (4) discharging. (2). PTO clutch engagement cylinder (3) with line (7) pressurized. (3). PTO clutch. (4). Clutch brake cylinder delivery line discharging. (5). Lubrication line with valve (8) for lubrication of front/rear bearings and clutch disks. (6). Position of accumulator cylinder for gradual PTO engagement with line (7) pressurized.

(7). Pressurized pump delivery line. (8). Position of lubrication valve (8) with line (7) pressurized (lubrication of front/rear bearings and clutch disks. (9). Lubrication line (5) external union. (10). Plug. (11). Threaded plug. (12). Flywheel drive shaft.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) control valve - Dynamic description and services spool valve with rod (4) in PTO synchronized with gearbox position hydraulic diagram Moving the synchronized PTO engagement lever fully upwards, engaged, the rod of the spool valve (4) is in the position shown in the figure. The line (11) receives pressurized oil from the pump, but the spool valve (4) closes the oil flow to the PTO clutch engagement cylinder delivery lines (2) and to the PTO clutch brake (3), connecting them with the discharge line (10) to the transmission casing, as shown in the drawing.

The oil under pressure from line (11) can moreover be used for the services of lines (8) and (9) . The figure shows solenoid valve (5) and (6) excited. With the solenoid valve (5) excited, the delivery line (9) is pressurized and the fourâ&#x2C6;&#x2019;wheel drive is disengaged. With the solenoid valve (6) excited, the delivery line (8) is pressurized and the front and rear differential lock is engaged.

SEZ31CAP2F-5

: Pressurised oil : Discharge oil (1). Oil delivery solenoid valve to PTO clutch or clutch brake (deactivated). (2). Delivery line (discharging) to the PTO clutch engagement cylinder. (3). Delivery line (discharging) to the clutch brake.

(6). Front or rear differential engagement command solenoid valve activated. (7). Control valve support.

(8). Pressurized delivery lines (front and rear differential engaged). (4). Control valve rod oil delivery to solenoid valve (1) in (9). Delivery line pressurized ( 4WD disengaged). PTO synchronized with gearbox position. (5). 4WD disengagement command solenoid valve (10). Outlet line to transmission casing. activated. (11). Delivery line from the pump to the services control valve (7).

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) speed rate selector - Adjust PTO gearbox flexible stay. 1.

Move the lever, in the cab, onto position 1000 RPM (fully forwards).

Move the lever, on the gearbox, onto position 1000 RPM (fully back).

Move the fork, for coupling to the gearshift, to a distance 210 mm (8.2677 in) from the retaining block.

Fix the cable to the retaining bracket.

Screw the fork in or out by 1/2 a turn at a time until you collimate the hole in the lever and insert the pin. Tighten the nut locking the fork.

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WLAPL4S31C210A

WLAPL4S31C211A

Power Take-Off (PTO) - Rear electro-hydraulic control

Synchronized Power Take-Off (PTO) controls - Adjust synchronized PTO cable flexible stay. 1.

Tighten the nut (1) locking the synchronized power takeâ&#x2C6;&#x2019;off lever coupling tie-rod, paying attention that the orientation of the lever is lengthwise with respect to the tractor's direction of travel.

Screw in the switch adjusting screw (2) completely.

Loosen the flexible cable fork tightening nut.

Connect the flexible cable to the lever and tighten the fork retaining nut.

Move the synchronized power takeâ&#x2C6;&#x2019;off coupling lever, on the gearbox, downwards to the limit stop, disengaged.

Unscrew the screw (1) until contact is made with the button, afterwards unscrew it by another 3 complete turns, then tighten the locknut.

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WLAPL4S31C12A

WLAPL4S31C213A

Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Troubleshooting Problem The independent PTO (commanded by the flywheel) does not work

The independent PTO (governed by the flywheel) stays on.

The PTO clutch drags.

Possible Cause Transmission oil level low.

Clogged oil filter. Hydraulic pump faulty. PTO engagement switch faulty. Lack of power supply to the solenoid valve: connections loose or damaged. Solenoid valve ( (1), Rear electro-hydraulic control - Static description and operation of the spool valve of the electro-hydraulically engaged PTO (31.104) ) governing the PTO clutch locked on delivery to brake. Oil leakage through the seals with consequent pressure drop: seal of the manifold, control plunger, etc. (see Power Take-Off (PTO) clutch - Sectional view (31.114), Power Take-Off (PTO) control valve - Hydraulic schema Hydraulic diagram with solenoid valve (energized). (31.104) ). PTO engagement switch faulty.

Solenoid valve governing the PTO clutch locked on delivery to clutch. Solenoid valve ( (1), Rear electro-hydraulic control - Static description and operation of the spool valve of the electro-hydraulically engaged PTO (31.104) ) governing the brake locked on delivery to clutch. Brake ( (24), Three-speed rear Power Take-Off (PTO) - Sectional view (31.116) ) of the PTO worn. 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. 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 - Dynamic description and services spool valve with rod (4) in PTO synchronized with gearbox position hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Power Take-Off (PTO) control valve - Hydraulic schema Hydraulic diagram with solenoid valve (de-energized) 14 Power Take-Off (PTO) control valve - Hydraulic schema Hydraulic diagram with solenoid valve (energized). . . 18 Power Take-Off (PTO) control valve - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Power Take-Off (PTO) speed rate selector - Adjust PTO gearbox flexible stay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Rear electro-hydraulic control - Dynamic description and operation with independent PTO or synchronized with the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rear electro-hydraulic control - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear electro-hydraulic control - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.95 NA, T5.105 NA, T5.115 NA

Rear electro-hydraulic control - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rear electro-hydraulic control - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear electro-hydraulic control - Static description and operation of the spool valve of the electro-hydraulically engaged PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rear electro-hydraulic control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Synchronized Power Take-Off (PTO) controls - Adjust synchronized PTO cable flexible stay. . . . . . . . . . . . . . . . . 24

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Power Take-Off (PTO) - 31 Three-speed rear Power Take-Off (PTO) - 116

T5.105 T5.115 T5.95

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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) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Three-speed rear Power Take-Off (PTO) Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - Torque

WLAPL4S31C201G

TORQUE WRENCH SETTINGS PARTS TO BE TIGHTENED Driven gear shaft locknut (C1) Clutch cover retaining bolts (C2) PTO guard retaining bolts (C3) PTO housing retaining bolts (C4)

Tightening torque

Thread

kgm

Nm (lbft) 294 N路m (216.84 lb ft)

25 N路m (18.44 lb ft)

2,6

25 N路m (18.44 lb ft)

2,6

M16X1.5

221 N路m (163.00 lb ft)

22,5

M28

1.5

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

PARTS TO BE TIGHTENED Retaining bolts for speed selection cable sheath bracket (C5) Rear bearing support retaining bolts (C6)

Tightening torque

Thread

kgm

Nm (lbft)

M10

1.25

55 N·m (40.57 lb ft)

5,6

M12

1.25

98 N·m (72.28 lb ft)

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - Sectional view rpm PTO sections at 540 - 540E - 1000

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

SEZ31CAP2H-1

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

(1). Driven shaft locking ring nut. (2). 540E RPM PTO coupling sleeve. (3). Rear driven gear 540E RPM. (4). Flywheel drive shaft. (5). Power take-off gearbox driving shaft (6). Driving gears 540E RPM . (7). Rear bearing support. (8). Oil delivery manifold on hydraulic cylinder (9). (9). Clutch engagement hydraulic cylinder (drive from flywheel). (10). Clutch disk disengagement spring ( (11) and (12)). (11). Clutch driving disk. (12). Clutch driven disk. (13). Clutch rear bearing. (14). Shaft guards (15). (15). PTO grooved terminal. (16). PTO output shaft retaining circlip (1). (17). Seal. (18). Driven gear front and central bushings (19). (19). Front driven gear 1000 RPM central driven gear 540 RPM . (20). PTO unit retaining bolt. (21). Driven gear rear bushing (3). (22). Driven shaft. (23). Rod stop cap (25) (2). (24). 540/1000 RPM engagement fork. (25). Fork sliding rod. (26). Speed selection lever pin. (27). Fork guide pin (24). (28). Speed selection internal plate. (29). Plate status cap (28). (30). Fork guide pin (31). (31). 540E RPM engagement fork. (32). Speed selection external lever. (1) After installing the circlip in its seat, turn it half way round until it is opposite the flat surface of the PTO output shaft in order to lock it. 84568014 22/03/2013

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

(2) Before screwing the cap onto the support, apply a few drops of LOCTITEÂ® 242 on its thread, then screw on fully but without tightening it.

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Index Power Take-Off (PTO) - 31 Three-speed rear Power Take-Off (PTO) - 116 Three-speed rear Power Take-Off (PTO) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Three-speed rear Power Take-Off (PTO) - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

T5.105 T5.115 T5.95

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Contents Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

TECHNICAL DATA Two-speed rear Power Take-Off (PTO) Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Power Take-Off (PTO) clutch General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Two-speed rear Power Take-Off (PTO) Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power Take-Off (PTO) clutch Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Output shaft Replace PTO splined output shaft and engagement modulation selection . . . . . . . . . . . . . . . . . . . . . . . . . 10

Power Take-Off (PTO) case Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Power Take-Off (PTO) clutch brake Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Torque

WLAPL4S31C201G

TORQUE WRENCH SETTINGS PARTS TO BE TIGHTENED Driven gear shaft locknut (C1) Clutch cover retaining bolts (C2) PTO guard retaining bolts (C3) PTO housing retaining bolts (C4)

Tightening torque

Thread

kgm

Nm (lbft) 294 N路m (216.84 lb ft)

25 N路m (18.44 lb ft)

2,6

25 N路m (18.44 lb ft)

2,6

M16X1.5

221 N路m (163.00 lb ft)

22,5

M28

1.5

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

PARTS TO BE TIGHTENED Retaining bolts for speed selection cable sheath bracket (C5) Rear bearing support retaining bolts (C6)

Tightening torque

Thread

kgm

Nm (lbft)

M10

1.25

55 N·m (40.57 lb ft)

5,6

M12

1.25

98 N·m (72.28 lb ft)

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - General specification ELECTRO--HYDRAULIC PTO CLUTCH UNIT DATA Models 65/88, 72/97, 77/105 KW/HP Clutch driving disk ( (11) , Three-speed rear Power Take-Off (PTO) - Sectional view (31.116) ) Mod. 77/105 KW/CV Mods. 65/88and 72/97 KW/CV Clutch driven disk ( (12) , Three-speed rear Power Take-Off (PTO) - Sectional view (31.116) ) Mod. 77/105 KW/CV Mods. 65/88 and 72/97 KW/CV

6 5

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Sectional view Cross--sectional views of 540 -- 1000 rpm PTO NORTH AMERICA

SEZ31CAP2G-5

(1). Flywheel drive shaft. (2). Retaining snap ring (3). (3). Bearing thrust ring. (4). PTO driving shaft, 540 RPM front gear ( z 15), 1000 RPM rear gear ( z 23). (5). Drive engagement clutch, governs the shaft (4). (6). Grooved terminal 34.925 mm (1.375 in) (6 grooves) for 540 RPM PTO or 34.925 mm (1.375 in) (21 grooves) for 1000 RPM PTO. (7). Driven shaft. 84568014 22/03/2013

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

(8). Splined output shaft retaining circlip (1). (9). Speed selection pin. (10). Speed selection sleeve control fork. (11). Return spring. (12). Speed selection fork control pin. (13). Speed selection support lever. (14). Speed selection lever, with adjustment cap (2). (15). Speed selection sleeve. (16). 1000 RPM driven gear ( z 52). (17). 540 RPM driven gear ( z 61). (1) After installing the circlip in its seat, turn it half way round until it is opposite the flat surface of the PTO output shaft in order to lock it. (2) To adjust cap (14) proceed as follows: - Mount the 1000 RPM PTO output shaft. - Screw the cap on flush with the sliding sleeve on the 1000 RPM driven gear. - Unscrew the cap by half a turn and lock it with the nut. NOTE: On assembly, apply the type of sealing compound noted In Basic instructions () on the surfaces marked with an X following the diagram in Power Take-Off (PTO) case - Install (31.114).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Sectional view Sectional views of PTO clutch unit

WLAPL4S31C201H

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

(1). Clutch. (2). Restrictor. (3). Oil drain valve. (4). Lubrication control valve. (5). Spring for valve (4). (6). Plug. (7). Lubrication oil inlet union. (8). Pressurized oil inlet union. (9). Brake oil inlet. (10). Power take--off clutch brake. (11). Restrictor (12). Spring and accumulator bottom. (13). Accumulator.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Output shaft - Replace PTO splined output shaft and engagement modulation selection To replace the output shaft (1) remove the special circlip (2); replace the shaft then fit the circlip back on. Two splined output shafts are available: • 3/8 " with 6 splines for power take−off working on 540 RPM , or 540E RPM . • 3/8 " with 21 splines for power take−off working on 1000 RPM . NOTICE: With power take−off working on 1000 RPM it is obligatory to fit the 21 splined output shaft. NOTE: In the North American markets the change in speed from 540 RPM to 1000 RPM is made by changing the output shaft. The 6-spline output shaft 3/8" for 540 RPM has a hole on the bottom, by fitting this output shaft, the driven shaft central pin of the PTO gearbox finds its housing in this hole and the speed selection coupling is left by the fork on the front of the gearbox, selecting the ratio for the 540 RPM. With the 21-spline output shaft 3/8" for 1000 RPM without the hole, slide the pin towards the front, tapping on the relay rod that moves the fork towards the rear, selecting the ratio for the 1000 RPM ( See Two-speed rear Power Take-Off (PTO) - Sectional view (31.104)

WLAPL4S31C209A

Independent power take-off speeds Operation on 540 RPM 540 RPM with engine on 1938 RPM 641 RPM with engine on 2300 RPM Operation on 540E RPM 540 RPM with engine on 1535 RPM 809 RPM with engine on 2300 RPM Operation on 1000 RPM 1000 RPM with engine on 1926 RPM 1194 RPM with engine on 2300 RPM

Synchronised power take−off speeds In any gear, the number of revolutions of the splined output shaft for one complete revolution of the rear wheels is as follows: • Operation at 540 RPM : 8.2 revs • Operation at 540E RPM: 11.7 revs • Operation at 1000 RPM: 14.7 turns

WLAPL4S31C206A

NOTE: : When the power take−off is used, the amber indicator on the instrument panel begins flashing the moment the maximum permissible rpm is exceeded. To avoid damage to the power take−off, never exceed the maximum permissible speeds. Should this occur, reduce the engine rpm to come back within the above values.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Selecting the power take−off smooth start function (engagement modulation) If you wish you can activate the power take-off modulated engagement function. With the modulating function engaged, when you engage the power take-off with the yellow knob, the drive is transmitted to the implement gradually without any kickback on either the power take-off or the implement. To activate the modulating function, use the button (1) . • Modulating function engaged = button in position (B) . • Modulating function disengaged = button in position (A) . NOTICE: the modulated engagement function can only be selected with the independent power take−off, controlled by the engine. WLAPL4S31C207A

WLAPL4S31C205A

Rear power take-off (PTO) external controls (if installed) On request, both rear mudguards can be fitted with a PTO button (6) , which helps align the PTO splined output shaft with the implement and facilitates static PTO applications. With the engine running, press the button momentarily to cause the PTO shaft to index round to align the shaft splines. If the button is pressed for less than 5 s , the shaft stops turning when the switch is released. Keeping the button pressed for between 5 - 12 s activates the PTO in continuous mode. Press the button again to stop the PTO. Alternatively, the P.T.O. may be stopped by means of the in- cab controls, as previously described. If the button is kept pressed for another 10 s, PTO operation is shut down. To restart, release the button and press it again. The PTO will now recommence turning. If more than 22 s elapse, it generates error code “ 5043 - Rear PTO fender switch stuck on”. Switch off the engine and restart it to delete the error and restore PTO control. The PTO may be engaged or disengaged with the button on the mudguard, whether the in-cab control is in the on or off position. Simultaneous operation, within two seconds, of in-cab and external PTO controls will result in an error code being displayed on the central LCD. A 10 s delay will occur before P.T.O. control operation will recommence. The soft start function will operate irrespective of whether the PTO is activated from inside the cab or with the button on the mudguard. NOTE: The warning light, on the P.T.O. control panel, will illuminate when the P.T.O. is engaged, momentarily or permanently.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) case - Remove ELECTRO--HYDRAULIC POWER TAKE--OFF HOUSING 1.

Operating the lever (1) , lift the steps, with the knob (2) , remove the battery cover, then detach the battery negative cable.

WLAPL4S31C201A

SEZ31CAP2A-27

SEZ31CAP2A-28

SEZ31CAP2A-29

Remove the tow bar and the top link on the three-point linkage device (1).

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

Remove the PTO speed sensor (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Fit a sling on the support with pick--up hitch hook (2), remove the six PTO casing retaining bolts (1) and detach the support with pick--up hitch hook.

SEZ31CAP2A-6

SEZ31CAP2A-30

SEZ31CAP2A-31

SEZ31CAP2A-32

Take out the four retaining bolts (1), remove the guard (2) on the PTO terminal.

Unscrew the unions and remove the three pipes (1) from the PTO.

Remove the PTO cover (4), take off the front circlip (3) and the support (2) of the clutch driving disks.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Remove the rear securing snap ring (1).

SEZ31CAP2A-7

10.

Hitch the PTO unit (1) to the lifting hook with chain 380000227, and allow the hoist to take the strain, unscrew the four bolts retaining the PTO unit to the transmission/gearbox casing and remove the PTO unit.

NOTE: Before removing the PTO unit, insert the PTO synchronized with gearbox lever, from inside the cab.

SEZ31CAP2A-33

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) case - Install 1.

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 indications given in 1.

Hitch the PTO unit 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 centering pins.

Remove the chain and secure the PTO with the four screws.

Remove the centering pins.

Place the stop ring (1) on the grooved shaft.

Refit the grooved support (2) on the PTO clutch and insert the retaining snap ring (3).

10.

SEZ31CAP2A-34

SEZ31CAP2A-32

SEZ31CAP2A-35

Carefully clean the contact surface the PTO cover ( (4), 2) and apply the sealing compound indicated in Basic instructions () of the diameter of 2 mm (0.079 in) along the marked line shown.

11.

Refit the cover ( (4), 2) and the PTO terminal guard.

12.

Refit the PTO speed sensor and secure with two bolts.

13.

Secure the PTO speed sensor electric cable bracket.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

14.

Refit the PTO lines (lubrication, clutch engagement and brake) on the PTO casing unions.

15.

Refit the tie--rod on the PTO speed selection external lever.

16.

Refit the sheath on the support bracket.

17.

Raise the support with pick--up hitch hook using a chain and secure to the PTO with the six retaining bolts.

18.

Refit the tow bar and the three--point linkage device tie--rod.

19.

Fill the transmission/gearbox casing with oil.

20.

Reconnect the negative battery lead.

21.

Respect the tightening torques listed in Three-speed rear Power Take-Off (PTO) - Torque (31.116) .

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) case - Disassemble ELECTRO--HYDRAULIC POWER TAKE--OFF HOUSING NOTE: PTO unit overhaul operations must be carried out on a workbench. 1.

Secure the PTO (1) in the vice on the workbench and detach lifting hook 380000227 with chain. Remove the securing ring and unscrew the driven shaft lock nut (2).

SEZ31CAP2A-36

SEZ31CAP2A-37

SEZ31CAP2A-38

Unscrew the fork (1) rod retaining Allen screw (3) on the (2).

Extract the rod (1) with a punch.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Remove the fork (2) and the engagement sleeve (1).

SEZ31CAP2A-9

SEZ31CAP2A-39

SEZ31CAP2A-40

SEZ31CAP2A-41

Remove the 750 RPM driven gear (1) and the bearing thrust ring.

Remove the retaining ring (2) and retrieve the support of the clutch driving discs with the related bearing (1).

Remove the external support with the hydraulic clutch disks (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

10.

11.

Using a mallet and punch, extract the speed selection (2) external lever securing pin (1) and remove the relevant parts.

SEZ31CAP2A-10

SEZ31CAP2A-42

Remove the snap rings (1) and (2) and extract the driving shaft (3) tapping on the end with a plastic mallet; remove gear unit (4).

Take out the four bolts (1) securing the gear support (2) With the pliers compress the terminal parts of the PTO terminal shaft, remove the snap ring and extract the shaft (3) from the rear part. Remove all parts, including the thrust washers.

SEZ31CAP2A-43

SEZ31CAP2A-44

Remove the retaining circlip (1) and extract the bearing (2) from the PTO cover.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

12.

13.

14.

15.

Using a screwdriver extract the oil seal (1) from the PTO cover.

SEZ31CAP2A-11

SEZ31CAP2A-45

SEZ31CAP2A-46

SEZ31CAP2A-12

With pliers, remove the snap ring (1) and the cover (2).

Tighten the screw (3) in the threaded hole on the piston (1), extract the piston and check the condition of the O--ring seal (2).

Remove the accumulator cap (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

16.

17.

18.

19.

Remove the accumulator components, i.e.: the piston (1), the spring (2), the cover (3).

SEZ31CAP2A-48

SEZ31CAP2A-49

SEZ31CAP2A-50

SEZ31CAP2A-13

Remove the snap ring (1) the clutch disks reaction ring (2), and the driving and driven clutch disks.

Fit spring press tool 380000243 (1) on the disks support (2) as shown in the figure, tighten the tool to compress the internal spring.

When possible, remove the snap ring (1) using a screwdriver. Loosen nut (2) and disassemble tool 380000243 (3).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

20.

21.

22.

Using a compressed air gun, expel the piston (1) from the disk support (2).

SEZ31CAP2A-51

SEZ31CAP2A-52

SEZ31CAP2A-53

Remove and check the condition of all parts, replacing O--ring seals (1) and (2), if necessary.

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.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) case - Assemble NOTE: Check the condition of all components, especially the clutches and seals, and replace any worn parts. Reassemble the parts comprising the PTO unit, proceeding as follows: 1.

For the correct orientation of the various parts, refer to Three-speed rear Power Take-Off (PTO) - Sectional view (31.116) , Power Take-Off (PTO) clutch - Sectional view (31.114) .

Insert the cylinder ( (9), Three-speed rear Power Take-Off (PTO) - Sectional view (31.116)) in the sliding seat, fit the spring (10) and the spring rear retaining plate.

Apply tool 380000243 (3), Power Take-Off (PTO) case - Disassemble (31.114)) as shown in the figure, tighten nut (2) to load the spring (10) and when possible, insert the retaining ring (1) on the spring rear plate (10), then remove tool 380000243.

Heat the intermediate bearing and fit on the shaft ( (5), Three-speed rear Power Take-Off (PTO) - Sectional view (31.116) ), then assemble the clutch control cylinder on the shaft (5).

Alternately mount the driven (12) and driving (11) disks on the clutch casing, fitting the external reaction ring ( (2), Power Take-Off (PTO) case - Disassemble (31.114) ) with the retaining snap ring (1).

Refit the piston, the spring and the accumulator cover Power Take-Off (PTO) case - Disassemble (31.114)).

Reassemble the brake and secure the cover with the snap ring, Power Take-Off (PTO) case - Disassemble (31.114)).

Refit the oil seal (1), Power Take-Off (PTO) case Disassemble (31.114)), using a punch to correctly position the seal.

Position the PTO cover in the vice, fit the rear bearing ( (2), Power Take-Off (PTO) case - Disassemble (31.114)) and the retaining snap ring (1).

10.

Assemble the speed selection lever ( (2), Power Take-Off (PTO) case - Disassemble (31.114)) on the cover and secure with the spring pin.

11.

Fit the spacer between the rear bearing and the driven gear 1000 RPM on the driven shaft ( (22), Three-speed rear Power Take-Off (PTO) - Sectional view (31.116) ).

12.

Assemble the 1000 RPM driven gear, complete with sleeve, fork and bushing.

13.

Partially insert the speed selection lever rod ( (1), Power Take-Off (PTO) case - Disassemble (31.114) ) so that the 540 and 1000 RPM gear engagement sleeve is held in position.

14.

Insert the 540 RPM gear and front bearing thrust washer on the shaft ( (22), Three-speed rear Power Take-Off (PTO) - Sectional view (31.116)).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

15.

Fit the gear support ( (2), Power Take-Off (PTO) case - Disassemble (31.114)) and bearings.

16.

Refit the driving shaft ( (3), Power Take-Off (PTO) case - Disassemble (31.114)) with the clutch disk locking cylinder (previously assembled), then gear unit (4) and the retaining snap rings (1) and (2).

17.

Position the spacer between the gear ( (3), Threespeed rear Power Take-Off (PTO) - Sectional view (31.116)) and the front bearing on the driven shaft.

18.

Fit the 750 RPM driven gear ( (1), Power Take-Off (PTO) case - Disassemble (31.114)), then the coupling sleeve ( (1), Power Take-Off (PTO) case - Disassemble (31.114)) and the fork (2).

19.

Fit the nut ( (2), Power Take-Off (PTO) case - Disassemble (31.114)) and tighten to the torque value indicated in Three-speed rear Power Take-Off (PTO) - Torque (31.116) securing the edge on the driven shaft thread to prevent the nut from loosening.

20.

Lock the fork support rod ( (3), Power Take-Off (PTO) case - Disassemble (31.114) ) with the retaining Allen bolt (*) on the support (2).

NOTE: For the assembly of the remaining parts refer to the respective installation operations (see figs. in Power Take-Off (PTO) case - Install (31.114) ). NOTE: (*) - Before screwing the cap onto the support, apply a few drops of LOCTITEÂŽ 242 on its thread, then screw on fully but without tightening it.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch brake - Replace POWER TAKE--OFF CLUTCH BRAKE 1.

Operating the lever (1) , lift the steps, with the knob (2) , remove the battery cover, then detach the battery negative cable.

WLAPL4S31C201A

SEZ31CAP2A-22

SEZ31CAP2A-23

SEZ31CAP2A-24

Detach the tow bar and the top link on the three-point linkage device (1).

Fit a sling on the support with pick--up hitch hook (2), remove the six PTO casing retaining bolts (1) and detach the support with pick--up hitch hook.

Remove the right--hand vertical tie--rod (1) from the lift arm, to have more room for subsequent disassembly.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Remove the brake cover retaining snap ring (1).

SEZ31CAP2A-4

SEZ31CAP2A-25

SEZ31CAP2A-26

Remove the cover (1) with a screwdriver

Screw bolt (1) on the brake piston threaded hole (2) and extract the piston using pliers.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch brake - Assemble 1.

Refit the brake, the cover and insert the brake cover retaining snap ring.

Reconnect the right--hand vertical tie--rod to the lift arm.

Refit the pick--up hitch hook.

Refit the tow bar and the three--point linkage device top link.

Re--connect the battery negative lead and fit the guard on the battery.

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Index Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114 Output shaft - Replace PTO splined output shaft and engagement modulation selection . . . . . . . . . . . . . . . . . . . . 10 Power Take-Off (PTO) case - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Power Take-Off (PTO) case - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Power Take-Off (PTO) case - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Power Take-Off (PTO) case - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Power Take-Off (PTO) clutch - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Power Take-Off (PTO) clutch - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Power Take-Off (PTO) clutch brake - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Power Take-Off (PTO) clutch brake - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Two-speed rear Power Take-Off (PTO) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Two-speed rear Power Take-Off (PTO) - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

84568014 22/03/2013 EN

SERVICE MANUAL Brakes and controls

T5.105 T5.115 T5.95

84568014 22/03/2013

Contents Brakes and controls - 33

[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 T5.105 , T5.115 , T5.95

[33.204] Front axle brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 T5.105 , T5.115 , T5.95

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3 T5.105 , T5.115 , T5.95

[33.220] Trailer brake hydraulic control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.4 T5.105 , T5.115 , T5.95

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Brakes and controls - 33 Hydraulic service brakes - 202

T5.105 T5.115 T5.95

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Contents Brakes and controls - 33 Hydraulic service brakes - 202

TECHNICAL DATA Hydraulic service brakes General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Hydraulic service brakes Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exploded view Diagram of seal compound application for brake assembly and final drives on the transmission casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Brakes Sectional view Service brakes sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Brake pedal control valve Dynamic description Pilot valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Brake pump Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Brake lines Hydraulic schema braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SERVICE Hydraulic service brakes Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Brake pedals Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Brake pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Brake lines Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Brakes and controls - Hydraulic service brakes

Hydraulic service brakes - General specification Type: - service brake Driving: - service brake Service brake disk material Quantity of disks: 4 WD - service brakes Hydrostatic control - Hydraulic pump - Operating pressure Brake on front axle Type Brake operation Quantity of disks Bleeding air from brake circuits Control pedal adjustment

with oil bath disk, acting on differential drive shafts hydrostatic, with independent pedals (connected by means of a pin) sintered 1 per side With 2 master cylinders independently operated by brake pedals 17.6 bar (255.20 psi) With oil bath disks, acting on differential drive shafts Hydrostatic, with paired pedals (by means of a pilot valve) 1 on each side see Brake lines - Bleed (33.202) see Brake pedals - Adjust (33.202)

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Brakes and controls - Hydraulic service brakes

Hydraulic service brakes - Dynamic description (see Brake lines - Hydraulic schema braking system (33.202)) The service brakes are the hydraulically operated wet disk type. The two control pumps (one for each pedal) are located in the front part of the cab and are connected to their pedals (6) by means of tie-rods. The pumps (9) can be operated on their own by each pedal, or as a pair with both pedals (connected by a pin (7) ). The connecting pipe (5) between the two pumps ensures balanced braking, even when the brake disks are not equally worn. The control pumps are fed from a single reservoir (10) installed on the pumps. The brake disks (one for each rear wheel) are located between the rear transmission casing and the final drive casing. The disks are mounted on the differential drive shafts.

Service brakes on front axle The service brakes on the front axle (four-wheel drive only), when fitted, are operated with the two rear brake pedals when they are pressed simultaneously (brakes locked). Pressing just one pedal (with the pedals free) produces no braking action on the front brake thanks to a pilot valve (15) ; the valve operation is described in Brake pedal control valve - Dynamic description Pilot valve operation (33.202).

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Brakes and controls - Hydraulic service brakes

Hydraulic service brakes - Exploded view Diagram of seal compound application for brake assembly and final drives on the transmission casing.

SEZ27CAP1F-5

The types of sealing compounds to be applied are specified in Basic instructions ().

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Brakes and controls - Hydraulic service brakes

Brakes - Sectional view Service brakes sectional drawings

WLAPL4S33C102H

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Brakes and controls - Hydraulic service brakes

(a) . Service brake. (1) . Brake wear disk. (3) . Service brake disc (5) . Brake piston (7) . Drive idle gear. (9) . Parking brake lever. (10) . Idle gear bearing. (12) . Drive driven gear (integral with (18) ). (15) . Handbrake shoe. (17) . Drive gear shaft (integral with (18) ). (19) . Parking brake lever shaft

(b) . PARKING BRAKE (2) . Hydraulic braking system pipe. (4) . Seal. (6) . Axle shaft (8) . Parking brake shoe and sector screws. (11) . Side mobile sector no. 2. (13) . Brake disc, no. 5 (integral with (18) ). (14) . Central mobile sector no. 5. (16) . Brake operating lever. (18) . Drive front gear/parking brake hub

NOTE: When mounting apply sealing compound to the surfaces as shown Hydraulic service brakes - Exploded view Diagram of seal compound application for brake assembly and final drives on the transmission casing. (27.120).

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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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Brakes and controls - Hydraulic service brakes

Brake pedal control valve - Dynamic description Pilot valve operation Brakes at rest. When the tractorâ&#x20AC;&#x2122;s brakes are at rest, there is no pressure on the pipes ( (A) - (B) - (C)).

SEZ33CAP1A-20OK

SEZ33CAP1A-21OK

SEZ33CAP1A-22OK

Braking applied on just one pedal. When pressing just one brake pedal (for instance, the one operating the right--hand rear brake), the pressure reaches the pilot valve through the pipe (B), shifts the ball (4) in contact with the tapered seat of the piston (3) bringing this into contact with the piston (1). No pressurized oil comes from the pipe (A), accordingly the ball (4) shifts the pin (5) and the ball (6) towards the piping (A). The oil pressure keeps the ball (4) in contact with the tapered seat of the piston (3) obstructing the flow of oil being delivered to the front brakes through the piping (C) and accordingly the front brakes are not subjected to braking.

Braking applied on both brake pedals. When both brake pedals are pressed, the pressurized oil reaches the pilot valve via both pipes ( (A) and (B)). The pressurized oil shifts the pistons ( (1) and (3)) towards the centre of the valve while the pin (5) keeps the balls ( (4) and (6)) detached from the tapered seats on the pistons ( (1) and (3)). In this position, the oil can arrive under pressure through the piping (C) with an according braking action of the front brakes.

: Tractor brake circuit oil (brakes off) : Tractor brake oil circuit (under pressure) (A). Oil from the left--hand brake cylinder. (B). Oil from the right--hand brake cylinder. (C). Oil delivered to the front brakes. (1). Left--hand piston. (2). Bleeding devices.

(3). (4). (5). (6).

Right--hand piston. Ball. Pin. Ball.

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Brakes and controls - Hydraulic service brakes

Brake pump - Sectional view Service brake sectional drawing

24664

(1). Spring. (2). Pump body. (3). Control piston.

(4). Rear seal. (5). Central seal. (6). Front seals.

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Brakes and controls - Hydraulic service brakes

Brake lines - Hydraulic schema braking system

WLAPL4S33C101H

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Brakes and controls - Hydraulic service brakes

(1) . - Front axle brakes bleeding compartment plug. (2) . - Oil line to the left brake piston. (3) . - Oil line to the right brake piston.

(18) . - Trailer brake valve operation rear brakes lines. (19) . - Trailer brake quick coupler. (20) . - Solenoid valve normally closed, Italian market trailer brake valve. (4) . - Oil distribution block on the lines. (21) . - Solenoid valve normally open, Italian market trailer brake valve. (5) . - Pressure balancing line on the right and left lines. (22) . - Pressure switch 3 bar (43.50 psi) (3,06 Kg/cm2) , Italian market trailer brake valve. (6) . - Brake pedals. (23) . - Trailer brake oil pressure line. (7) . - Brake pedals coupling pin. (24) . - Trailer brake valve. (8) . - Brake pedal switches. (25) . - Bleed screws. (9) . - Brake pumps. (26) . - Mechanical brakes release pressure regulating valve 10.9 - 11.6 bar (158.05 - 168.20 psi) (11,11 รท 11,82 Kg/cm2) . (10) . - Brake fluid reservoir. (27) . - Oil line to the rear brakes. (11) . - Brake fluid level float. (28) . - Italian market application spool valve. (12) . - Rear brakes oil line to the pilot valve. (A) - View of trailer brake valve. (13) . - Oil line from the pilot valve to the front brakes. (N) - Oil not used to the lift and spool valves. (14) . - Pilot valve bleed screws. (P) - oil from pump. (15) . - Pilot valve. (R) Oil to discharge. (16) . - Pressure switch 10 bar (145.00 psi) (10,19 (a) - Pipes from the brake pumps to the rear brakes. Kg/cm2) , Italian market trailer brake valve. (17) . - Bleed screws on the rear brakes. (b) - line from the pilot valve to the oil distribution block on the front brake lines.

NOTE: The buttons, fitted on the brake pedals, must be fitted so that, with the pedals released, the button feeler gets pressed. These have 4 pins: with pedals released, pin 1 and 4 are normally closed, pin 2 and 3 are normally open. Pin 1 is supplied, pin 4 is connected to the gearbox control unit. Pin 2 is supplied and pin 3 is connected to the brake lights, which come on when one or both pedals are pressed.

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Brakes and controls - Hydraulic service brakes

Hydraulic service brakes - Remove To remove the brake, proceed as follows: 1.

Detach the final drive box assembly as shown in the procedure Final drive housing - Remove (27.120).

MOIL12APL0040AA

MOIL12APL0034AA

MOIL12APL0035AA

MOIL12APL0036AA

Remove the union (2), and detach the service brake control piping (1).

Detach the ring gear (1), the spacer (3) and the brake disc (2), from the transmission--gearbox casing.

Remove the differential lock piping (1) from the union (2), turn this to free the friction disk (3) and be able to remove it.

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Brakes and controls - Hydraulic service brakes

Hydraulic service brakes - Install To refit the final drive casing and the brakes to the rear transmission casing, proceed as follows: 1.

Refer to the illustration of fig. Brakes - Sectional view Service brakes sectional drawings (33.202) for the correct orientation of the various components.

Before reassembling the final drive casing to the rear transmission casing, carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 2 mm (0.0787 in)) along the marked line shown in the illustration of fig. Hydraulic service brakes - Exploded view Diagram of seal compound application for brake assembly and final drives on the transmission casing. (27.120).

Check the seals and replace if damaged.

Respect the tightening torques prescribed on page Parking brake or parking lock - Torque (33.110)

Insert the wear disk, rotate the union and refit the differential lock line.

Fit the brake disk, spacer and crown gear.

Connect the service brake lines.

To reconnect the final drive assembly, follow the procedure given on page. Final drive housing - Install (27.120).

Bleed air from the brake circuit Brake lines - Bleed (33.202)

10.

Fill the brake fluid tank: the prescribed product and the relevant quantity are given in Consumables ()

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Brakes and controls - Hydraulic service brakes

Brake pedals - Adjust 1.

Move the feelers (1) into contact on the bracket of the pedal; connect the pedals to the forks of the pumps (4) and to the return springs (2) ; insert the bolt (3) locking the pedals, if it does not enter, take the lowest pedal and, working on the fork of the pump, tightening by half a turn at a time, it is not possible, after reconnecting the fork, to insert the bolt.

NOTE: the pump comes with the forks already adjusted. Again with the pedals released, tighten the feelers until you hear the switch trip. Afterwards, tighten the feelers by another three full turns and screw on the locknut. NOTE: The switches must be mounted in the condition of already being pressed, this is for reasons of safety, if the switches should for any reason break, the front-wheel drive remains constantly engaged, instead of engaging only while braking with both pedals. 2.

WLAPL4S33C105A

WLAPL4S33C106A

With the pedals released, pass a bar of thickness 2 mm (0.0787 in) between the feelers (1) and the end of the switches (2) . Observe that during this operation the pedal does not move, but the ends of the switches return. If the opposite happens it means that the ends of the switches are already at the limit stop, repeat the adjustment.

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Brakes and controls - Hydraulic service brakes

Brake pump - Remove To remove the hydraulic pump, proceed as follows: 1.

Carry out the Cab with platform unit operation, only removal (see, 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.

MOIL12APL0045AA

MOIL12APL0046AA

MOIL12APL0047AA

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).

Mark and disconnect the connections of the ignition block (3).

Detach the rear guard (4) of the steering column.

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Brakes and controls - Hydraulic service brakes

Disconnect the control pipes (1) from the service brakes control pumps.

10.

Disconnect the pipes (2) connecting the brake pumps to the brake fluid reservoir, taking care to press the tube and bend it upwards so as to avoid oil leakage.

11.

12.

MOIL12APL0048AA

MOIL12APL0049AA

MOIL12APL0050AA

Disconnect the brake control pedals (1) from the pumps (2) unscrew the relevant fixing screws and remove them.

Remove the brake pumps assembly, detach the connecting pipe (1) to separate them.

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Brakes and controls - Hydraulic service brakes

Brake pump - Install To refit the brake control hydraulic pump unit, proceed as follows: 1.

Connect the two brake pumps using the connection pipe.

Position the brake pumps and secure them, connect the relevant control pedals. Adjust the brake pedals as required in Brake pedals - Adjust (33.202).

Position and secure the rear guard of the steering column.

Position and secure the ignition block and connect the relevant electrical connections.

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 guard on the instrument cluster.

Position and secure the steering wheel, fit the cover with the logo on the steering wheel.

10.

Carry out operation 90 150 10 (see, Cab and platform - Install (90.150)) Cab with platform unit, only installation.

11.

Fill the brake fluid tank: the prescribed product and the relevant quantity are given in (see, Consumables ().

12.

Check the braking system bleed valves as per (see, Brake lines - Bleed (33.202).

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Brakes and controls - Hydraulic service brakes

Brake lines - Bleed Air bleed NOTE: Air must be bled out whenever carrying out work on the brake hydraulic system. 1.

Thoroughly clean the external parts of the assemblies near the bleeding screws ( (1), 2 ) and the hydraulic oil reservoir cover (1).

Check that the right--hand brake reservoir (1) is full, both before and during bleeding.

WLAPL4S33C101A

WLAPL4S33C102A

WLAPL4S33C103A

NOTE: Carefully filter used oil before re--using. 3.

Push the left--hand brake pedal down, slowly and fully, so that the oil is put in pressure.

Keep the pedal pressed down, unscrew the bleeding screw (1)by half a turn, allowing the oil/air bubble mixture to flow out.

Tighten the screw (1) and repeat the aforementioned operation until oil without air bubbles flows out.

Push the left brake pedal down again so that the oil is put under pressure: this occurs when the brake pedal stroke returns to normal.

Repeat the above steps for the right--hand brake pedal.

On completion of this procedure, fill up the reservoir with oil ( (1), 1 ).

Tractors equipped with hydraulic trailer braking valve. 9.

When the tractor is equipped with a trailer braking hydraulic spool valve, carry out the operation described above (from operation 3 . to 6 .) on the right and left pedal and bleed the air from the respective screws ( (3) and (1) 3). Subsequently connect the pedals, and with the pedals connected repeat the bleeding operations making the air come out from the bleeder screw ( (2) , 3).

10.

On completion of this procedure, fill up the reservoir with oil ( (1), 1).

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Brakes and controls - Hydraulic service brakes

Tractor equipped with brakes on the front axle 11.

Under the hood on the left-hand side there is the pilot valve that, with the pedals coupled, enables braking on the front axle. Each one of these screws ( (1) and (2) , 4 ) is coupled with the circuit of a single pedal. Repeat operations 3 . to 6 . for each you pedal, bleeding the circuit.

12.

On the hub of each wheel of the front axle there is a plug (1), if it is not visible then turn the wheel to bring it round to the top. On the inside there is a bleed screw, after removing the plug, turn the wheel slightly to bring the hole into position with the screw.

13.

On these two screws, one on each side, it is Necessary to do the bleeding as described above except that the pedals must be paired therefore bleed first one screw and then the other one with the pedals paired.

14.

On completion of this procedure, fill up the reservoir with oil ( (1), 1 ).

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WLAPL4S33C104A

SEZ33CAP1A-28

Index Brakes and controls - 33 Hydraulic service brakes - 202 Brake lines - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Brake lines - Hydraulic schema braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Brake pedal control valve - Dynamic description Pilot valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Brake pedals - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Brake pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Brake pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Brake pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Brakes - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Brakes - Sectional view Service brakes sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic service brakes - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic service brakes - Exploded view Diagram of seal compound application for brake assembly and final drives on the transmission casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic service brakes - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic service brakes - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Brakes and controls - 33 Front axle brake - 204

T5.105 T5.115 T5.95

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Contents Brakes and controls - 33 Front axle brake - 204

FUNCTIONAL DATA Front axle brake Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.

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Brakes and controls - Front axle brake

Front axle brake - Sectional view T5.

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 Front axle brake - 204 Front axle brake - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T5.

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Brakes and controls - 33 Parking brake or parking lock - 110

T5.105 T5.115 T5.95

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Contents Brakes and controls - 33 Parking brake or parking lock - 110

TECHNICAL DATA Parking brake or parking lock General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Parking brake or parking lock Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional view Parking brakes sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Parking brake disks Sectional view Parking brakes sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Parking brake external control Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - General specification Type: -- parking brake Driving: -- parking brake Parking brake disk material Parking brake mobile sectors material Quantity of disks: 4 WD - parking brake

with oil bath disks, engaging a gear on the bevel pinion shaft mechanical, by means of a hand lever steel sintered or organic agglomerate 5

Parking brake or parking lock - Torque

SEZ33CAP1F-1

Tightening torque Nm

kgm

M 14 x 1.5

176

M 10 x 1.25

6.5

M 12 x 1.25

3.2

M 12 x 1.25

M 10 x 1.25

75 to 82

7.6 to 8.4

PARTS TO BE TIGHTENED Thread Nut securing final drive to transmission casing (C1) Bolts retaining shaft for parking brake driven gear (C2) Guide bolts for parking brake mobile sector (C3) Bolt retaining parking brake support to transmission casing (C4) Brake piston /stub axle retaining bolt (C5)

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Dynamic description (see Brakes - Sectional view Service brakes sectional drawings (33.202)) The parking brake is operated by a control lever on the left-hand side of the operator. When acting on the control lever, a flexible tie-rod operates the lever (12) inside the parking brake support (13) , bearing the brake sector assembly ( (10) and (11) ) and the brake disks (8) keyed onto the front gear of the drive / brake hub (18) and locking it. Locking the gear (18) also locks the drive gear shaft idle gear (7) , causing the bevel pinion and therefore the tractor to shut down.

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Sectional view Parking brakes sectional drawings

WLAPL4S33C102H

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Brakes and controls - Parking brake or parking lock

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Brakes and controls - Parking brake or parking lock

Parking brake disks - Sectional view Parking brakes sectional drawings

WLAPL4S33C102H

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Brakes and controls - Parking brake or parking lock

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Brakes and controls - Parking brake or parking lock

Parking brake external control - Adjust 1.

When fitting the lever (1) , in the cab, screw on the fork to a distance (L) = 25 mm (0.9843 in) from the top fork, after which tighten the retaining nut.

Lower the lever and move it to the first click.

Fit the flexible cable on the reaction bracket.

Using the adjuster nuts ( (1) and (2) ) move the handbrake cable adjustment at the limit stop towards the dust seal.

Unhook the return spring, keep the lever on the transmission raised upwards as far as the mechanical stop.

Unscrew the nut (2) until the cable fork is collimated with the hole on the lever and insert the pin, tighten the nut (1) .

WLAPL4S33C107A

WLAPL4S33C108A

WLAPL4S33C109A

Release the lever in the cab, reattach the handbrake return spring.

Fault indicators Due to incorrect operations by the operator, the display may show the following fault codes: A - see 1 Request for starting without using the clutch pedal with the handbrake engaged, it disappears when the brake is released.

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Brakes and controls - Parking brake or parking lock

B - see 2 With the engine running and the key ON if the operator leaves the seat or if a fault occurs on the seat switch, the display will show the icon in the figure. brake faults

WLAPL4S33C110A

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Index Brakes and controls - 33 Parking brake or parking lock - 110 Parking brake disks - Sectional view Parking brakes sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Parking brake external control - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Parking brake or parking lock - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Parking brake or parking lock - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Parking brake or parking lock - Sectional view Parking brakes sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Parking brake or parking lock - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Brakes and controls - 33 Trailer brake hydraulic control - 220

T5.105 T5.115 T5.95

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Contents Brakes and controls - 33 Trailer brake hydraulic control - 220

TECHNICAL DATA Trailer brake valve Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Trailer brake hydraulic control Hydraulic schema (view of Italian trailer brake assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Trailer brake valve Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SERVICE Trailer brake hydraulic control Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

DIAGNOSTIC Trailer brake valve Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Brakes and controls - Trailer brake hydraulic control

Trailer brake valve - Torque

WLAPL4S35C401E

Fixing screw (C1) Logic head fixing valve (C2) Union (C3) Union (C4)

20 - 25 N·m (14.75 - 18.44 lb ft) 10 - 13 N·m (7.38 - 9.59 lb ft) 56 - 75 N·m (41.30 - 55.32 lb ft) 14 - 19 N·m (10.33 - 14.01 lb ft)

(2,03 ÷ 2,54 Kgm) (1,01 ÷ 1,32 Kgm) (5,71 ÷ 7,65 Kgm) (1,43 ÷ 1,94 Kgm)

Trailer brake valve - Special tools • 380000240 : Universal pressure testing kit.

Trailer brake valve - General specification Trailer brake valve 150 bar (2175.00 psi) (152,9 Kg/cm2) 3 bar (43.50 psi) (3,06 Kg/cm2) Italian version trailer brake Mechanical brake release pressure switch 10 bar (145.00 psi) (10,19 Kg/cm2) Mechanical brakes release pressure regulating valve 10.9 - 11.6 bar (158.05 - 168.20 psi) (11,11 ÷ 11,82 Kg/cm2) Trailer brake maximum pressure Oil Pressure Switch

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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

On operating the brake pedals, the pressure generated in line (A), closes the valve (6) return union (R) and consequently the pressure in the delivery line from the hydraulic pump (9) increases. The pressurized oil ( 12 - 150 bar (174.00 - 2175.00 psi) flows out of the trailer brake valve (7) through line (B) to solenoid valve (5a), which is open, and through line (15) to the trailer brake, where it overcomes the resistance of the springs ( (17) and (19)) to shift the piston (18) and thus brake the trailer.

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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 - Sectional view Cross-sectional view of auxiliary control valve for trailer brakes. (1). Non-return valve. (2). Flow regulator. (3). Pilot valve casing. (4). Pilot valve piston. (5). Pressure limiter. (6). Slide piston.

SEZ35CAP3A-28

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Brakes and controls - Trailer brake hydraulic control

Trailer brake valve - Static description The trailer brake valve is located under the cab, in the middle of the transmission casing, immediately attached to the front of the base of the turret of the supplementary spool valves, and takes priority of service over both the auxiliary spool valves and the hydraulic lift. For the hydraulic operation of the trailer brake valve, see Trailer brake valve - Dynamic description (33.220) . The ITALIA trailer brake valve version provides the advantage and safety of having the trailer braked even with: - engine off; - pump failure (or insufficient flow rate). See Trailer brake hydraulic control - Hydraulic schema (view of Italian trailer brake assembly) (33.220) for a description of the circuit, whereas for operation see Trailer brake hydraulic control - Dynamic description (33.220) .

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Brakes and controls - Trailer brake hydraulic control

Trailer brake hydraulic control - Pressure test Test conditions Oil temperature 40 - 50 °C (104.00 - 122.00 °F).. Engine rpm: 1000 RPM. Electrical system powered. Parking brake disengaged.

Trailer brake release pressure test. 1.

Insert the fitting (1) in the trailer brake coupling and connect it to the pressure gauge with scale 0 - 40 Kg/cm² (0.00 - 568.93 psi) from the pressure test kit.

With the engine and oil at the aforementioned conditions, the pressure should be 11 - 12 bar (159.50 174.00 psi).

Check that the warning light ( (22), last illustration in Trailer brake hydraulic control - Dynamic description (33.220) ) is not illuminated.

Apply the parking brake and disconnect the pressure gauge and union 293190 (1).

SEZ35CAP4A-1

TESTING THE SETTING OF THE TRAILER BRAKE SYSTEM PRESSURE CONTROL VALVE INCORPORATED IN THE TRAILER BRAKE CONTROL VALVE 1.

Insert the fitting (1) in the trailer brake coupling and connect it to the pressure gauge with scale 0 - 40 Kg/cm² (0.00 - 568.93 psi) from the pressure test kit.

SEZ35CAP4A-1

With the engine and the oil in the conditions described at the beginning of the chapter, apply a force of 300 - 350 N (67.44 - 78.68 lb) to the service brake pedals; the pressure reading on the gauge must be 135 - 145 bar (1957.50 - 2102.50 psi).

Apply the parking brake and disconnect the pressure gauge and fitting (1) .

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Brakes and controls - Trailer brake hydraulic control

CHECKING THAT TRAILER BRAKE RELEASE PRESSURE IS NULLIFIED WHEN THE PARKING BRAKE IS APPLIED 1.

Insert the fitting (1) in the trailer brake coupling and connect it to the pressure gauge with scale 0 - 40 Kg/cmÂ˛ (0.00 - 568.93 psi) from the pressure test kit.

With the engine and the oil in the conditions described at the beginning of the chapter, fully pull the parking brake lever ( (1), last illustration in Trailer brake hydraulic control - Dynamic description (33.220)).

Check that the pressure is 0 bar (0.00 psi) and that warning light ( (22), last illustration in Trailer brake hydraulic control - Dynamic description (33.220) ) is ON.

With the parking brake applied, disconnect the pressure gauge and the fitting (1).

NOTE: The switch (8) can be identified by the red paint mark between the two terminals.

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SEZ35CAP4A-1

Brakes and controls - Trailer brake hydraulic control

Trailer brake hydraulic control - Leakage test Hydraulic system leakage test 1.

Insert union 293190 (1) in the trailer brake coupling and connect to the pressure gauge with scale 0 - 250 Kg/cmÂ˛ (0.00 - 3555.84 psi) from kit 380000240.

SEZ35CAP4A-1

With the engine and the oil in the test conditions described at the beginning of the chapter, apply a force of 300 - 350 N (67.44 - 78.68 lb) to the service brake pedals and with a pressure of 135 - 145 bar (1957.50 - 2102.50 psi) check that within 10 s the number of pressure peaks is under 10.

Apply the parking brake and disconnect the pressure gauge and union 293190 (1).

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Brakes and controls - Trailer brake hydraulic control

Trailer brake hydraulic control - Electrical test Check calibration on switches ( (8) and (16), last illustration in Trailer brake hydraulic control - Dynamic description (33.220) ). 1.

Insert the fitting (1) in the trailer brake coupling and connect it to the pressure gauge with scale 0 - 40 Kg/cmÂ˛ (0.00 - 568.93 psi) from the pressure test kit.

Without applying the service and parking brakes, operate the control lever of an auxiliary control (until the corresponding pressure relief valve is activated), hold this position for a few seconds then suddenly release the control lever.

SEZ35CAP4A-1

Check that the parking brake release pressure remains at the prescribed level of: 11 - 12 bar (159.50 - 174.00 psi).

Apply the parking brake and disconnect the pressure gauge and fitting (1) .

NOTE: The switch (8) can be identified by the red paint mark between the two terminals.

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Brakes and controls - Trailer brake hydraulic control

Trailer brake valve - Troubleshooting Problem Possible Cause Trailer brake release Parking brake ( (1), last illustration in pressure = 0 bar (warning Trailer brake hydraulic control - Dylight, (22) last figure in namic description (33.220)) engaged. Trailer brake hydraulic control - Dynamic description (33.220) ON). Trailer brake release pressure control valve (6) incorrectly adjusted. Trailer brake circuit safety switch (8) faulty. Hydraulic pump (9) faulty. Delivery line solenoid valve (5a) locked in closed position. Discharge line solenoid valve (5b) locked in open position. Trailer brake pressure Trailer brake release pressure control valve release 0 - 11 bar (0.00 - (6) incorrectly adjusted. 159.50 psi). Trailer brake release Trailer brake warning light switch (16) pressure correct, but faulty. warning light ( (22), last illustration in Trailer brake hydraulic control - Dynamic description (33.220)) illuminated. Trailer brake release Warning light (22) bulb faulty. pressure incorrect, but warning light ( (22), last illustration in Trailer brake hydraulic control - Dynamic description (33.220)) not illuminated. Trailer brake warning light switch (16) faulty. Pressure above or below Pressure control valve ( (6), last illustraprescribed range. tion in Trailer brake hydraulic control Dynamic description (33.220)) of trailer brake auxiliary control valve faulty. Hydraulic pump (9) faulty. When the parking brake is Parking brake switch ( (21), last illustration applied the trailer brake in Trailer brake hydraulic control - Dyrelease pressure is not namic description (33.220)) faulty. nullified. Parking brake indicator relay (2) faulty. Discharge line solenoid valve (5b) locked in closed position or faulty. On carrying out the Trailer brake circuit safety switch ( (8), last operation "CALIBRATION illustration in Trailer brake hydraulic conON SWITCHES", the trailer trol - Dynamic description (33.220)) setbrake release pressure is ting higher than the nominal pressure ( 3 nullified permanently. bar (43.50 psi) Âą 0.5 bar (7.25 psi)). Switches ( (8) and (16)) installed in incorrect positions, or electrical leads connected incorrectly. On applying the Oil leaks in the hydraulic system. prescribed force on the service brake pedals, there are an excessive number of pressure peaks over a 10-second period 84568014 22/03/2013

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Correction Release the parking brake.

Renew it. Replace switch. Overhaul or replace hydraulic pump. Free or replace the solenoid valve. Free or replace the solenoid valve. Renew it.

Replace switch.

Change the lamp bulb.

Replace switch. Replace trailer brake auxiliary control valve.

Replace the pump. Replace switch.

Replace that relay. Free or replace the solenoid valve. Replace switch.

Install the two switches in their correct positions or swap over the electrical power leads. Find and eliminate the leaks.

Brakes and controls - Trailer brake hydraulic control

Problem

Possible Cause Correction Excessive leakage from the solenoid valve Replace solenoid valve. ( (5b), last illustration in Trailer brake hydraulic control - Dynamic description (33.220) ). Excessive leakage from trailer brake con- Replace trailer brake auxiliary control valve. trol valve (7).

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Index Brakes and controls - 33 Trailer brake hydraulic control - 220 Trailer brake hydraulic control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Trailer brake hydraulic control - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Trailer brake hydraulic control - Hydraulic schema (view of Italian trailer brake assembly) . . . . . . . . . . . . . . . . . . . . 4 Trailer brake hydraulic control - Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Trailer brake hydraulic control - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Trailer brake valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Trailer brake valve - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Trailer brake valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Trailer brake valve - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Trailer brake valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Trailer brake valve - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

84568014 22/03/2013 EN

SERVICE MANUAL Hydraulic systems

T5.105 T5.115 T5.95

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 T5.105 , T5.115 , T5.95

[35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 T5.105 , T5.115 , T5.95

[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 T5.105 , T5.115 , T5.95

[35.114] Three-point hitch control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 T5.105 , T5.115 , T5.95

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T5.105 T5.115 T5.95

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Contents Hydraulic systems - 35 Hydraulic systems - 000

TECHNICAL DATA Hydraulic systems General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Hydraulic systems Static description power steering / low pressure, high pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic schema , transmission general hydraulic system, 24X24 version . . . . . . . . . . . . . . . . . . . . . . . . 11

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Hydraulic systems - Hydraulic systems

Hydraulic systems - General specification Power steering / low pressure Type Location Pump Type Location Manufacturer Method of operation 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 nominal flow rate for new pump Filter

Filter paper cartridge fixed to the pump body on suction side gear type with oil suction from transmission casing Flanged on the front left-hand side of the engine Bosch−Rexroth by means of the engine timing gears Clockwise 1 : 1.125 2587 RPM 14.62 cm³/rev (0.8922 in³/rev) 37.82 l/min (9.9910 US gpm) Paper, interchangeable, after removing the metal container. Fitted on the right-hand side of the engine on the power steering outlet pipe (filter on delivery)

Type Location Clutches and services pressure regulating valves

Location

Calibrate Lubrication pressure regulating valves

Fitted on the front of the gearbox spool valve at the oil inlet tube. (see fig. 6, Hydraulic systems - Static description power steering / low pressure, high pressure (35.000)) 18 bar (261.00 psi) Fitted on the gearbox main shaft lubrication manifold immediately after the clutches of the power shuttle (see fig. 8, Hydraulic systems - Static description power steering / low pressure, high pressure (35.000)) 2.9 - 3.7 bar (42.05 - 53.65 psi)

Location Calibrate

High Pressure Circuit Filter Type Location

paper cartridge fixed to the pump body on suction side

Pump Type gear type with oil suction from transmission casing Location Flanged on the front left-hand side of the engine Bosch−Rexroth Manufacturer Method of operation by means of the engine timing gears 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 25.45 cm³/rev (1.5531 in³/rev) Corresponding nominal flow rate for new pump 65.86 l/min (17.40 US gpm) Pressure regulating valves on the pump

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Hydraulic systems - Hydraulic systems

Location

Fitted on the filter support at the oil delivery to the services. (see fig. 12, Hydraulic systems - Static description power steering / low pressure, high pressure (35.000)) Calibrate 190 - 195 bar (2755.00 - 2827.50 psi) Pressure regulating valves on the spool valve turret Location Fitted on the load sensing line in the base of the turret. (see fig. 14, Hydraulic systems - Static description power steering / low pressure, high pressure (35.000) ) Calibrate 190 - 195 bar (2755.00 - 2827.50 psi)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Static description power steering / low pressure, high pressure Power steering / low pressure system 1. The power steering pump (1) draws oil from the pipe (2) and via the pipe (3) sends it to the power steering spool valve.

WLAPL4S35CX01A

WLAPL4S35CX02A

WLAPL4S35CX03A

2. Underneath the pump there is a filter (1) , through which flows the oil under suction from the transmission casing through the pipe (3) , and following the pipe (2) it sends it to the pump. If there is a delay in the replacement, the filter is equipped with a by-pass valve that allows the oil to flow, even if not filtered, provided that there is a difference in pressure between the filter intake and delivery of 0.8 bar (11.60 psi) (0,81 Kg/cm2) .

3. The power steering spool valve (1) receives oil (2) from the pump: the lines (3) are used for steering right and left, the oil being discharged leaves the pipe (4) and is used for the low pressure services.

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Hydraulic systems - Hydraulic systems

4. The power steering outlet (3) is fitted with a delivery filter (1) on the right-hand side of the engine. Flowing through the pipe (2) the oil reaches the spool valve of the gearbox.

WLAPL4S35CX04A

WLAPL4S35CX05A

WLAPL4S35CX06A

WLAPL4S35CX07A

5. Flowing through the pipe (1) and the column (2) some of the oil enters the spool valve of the gearbox, while the remainder flowing through the line (3) reaches the services spool valve. NOTE: The image shows the spool valve of the 24X24, with 4 solenoid valves, in the two remaining series, 12X12 and 20X20, while the spool valve changes, the routing is identical.

6. The oil coming in from the column ( (2) , 5 ) works on the cap (3) and given the load of the spring (1) the services and clutch engagement is regulated to the working pressure 18 bar (261.00 psi) (18,35 Kg/cm²) .

7. The excess oil, when cold and therefore denser, flows through the by-pass valve ( (2) , 6 ) to enter into the lubrication manifold of the transmission shaft then the gearbox main shaft and part of it, via the column (3) and the pipe (4) , lubricates the power take−off. On the contrary, when the oil is hot and therefore more fluid, no longer being able to open the by-pass valve, calibrated to 3.5 bar (50.75 psi) (3,57 Kg/cm2) , ( (2) , 6), it leaves the pipe (1) goes onto the cooler, cools and, returning from the (2) , part of it goes to the power take−off via the (4) and part of it goes back up the column (3) and enters the gearbox.

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Hydraulic systems - Hydraulic systems

8. Once the oil enters the main shaft lubrication manifold (1) it acts on the lubrication pressure regulating valve (2) and calibrates to a pressure of 2.9 - 3.7 bar (42.05 - 53.65 psi) (3 ÷ 3,8 kg/cm2) .

WLAPL4S35CX08A

WLAPL4S35CX09A

9. The oil from the pipe (1) enters the services spool valve. From the pipe (2) it packs the power take−off clutch and simultaneously the null pressure pipe (3) frees the power take−off brake. The pipe ( (4) and (5) ) go respectively to the rear and front differential lock, if fitted. The oil goes from the pipe (6) to disengage the frontwheel drive.

10. Looking at the tractor from the back, the line (1) carries oil to the power take−off lubrication, (2) to the clutch, and (3) to the brake.

WLAPL4S35CX10A

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Hydraulic systems - Hydraulic systems

High Pressure Circuit 1. The lift pump (1) draws oil from the pipe (2) and via the pipe (3) sends it to the base of the turret EDC / spool valves.

WLAPL4S35CX11A

WLAPL4S35CX12A

WLAPL4S35CX13A

WLAPL4S35CX14A

2. The support of the filter (1) is fitted with the pressure regulating valve (2) that regulates the pressure to 190 - 195 bar (2755.00 - 2827.50 psi) (193,7 ÷ 198,8 Kg/cm²) .

3. The oil flows through the pipe (1) to the base of the turret (2) of the spool valves / EDC , and through the pipe (3) it reaches the ventral spool valves.

4. On the base of the turret (1) there is a second relief valve (2) , which is also calibrated to 190 - 195 bar (2755.00 - 2827.50 psi) (193,7 ÷ 198,8 Kg/cm²) . Inside this base there is a flow regulating valve that sends the oil to the spool valves, to the electronic lift (EDC) and to the ventral spool valves, if fitted, only if these, via the load sensing line, request it otherwise it sends it for discharge.

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Hydraulic systems - Hydraulic systems

5. The trailer brake valve is secured on the front of the turret base ( (1) , 14 ). The oil reaches the base and immediately, on crossing it, it reaches this valve, for reasons of safety the valve is the priority user of the high pressure circuit. The image shows the Italian version of the trailer brake valve with its spool valve (2) .

WLAPL4S35CX15A

WLAPL4S35CX16A

WLAPL4S35CX17A

WLAPL4S35CX18A

6. Immediately above the base there is the spool valve of the electronic lift (EDC) for closed center, with the two lifting and lowering solenoid valves. From the pipe (2) the oil under pressure reaches the front of the lift box, it enters the box and feeds the lifting cylinder and, if fitted, feeds the supplementary cylinders on the vertical arms of the lift.

7. Above the lift is secured up to a group of three spool valves (1) , which are also for a closed center, fitted with a configurable lever holding device.

8. On the last spool valve in the group it is possible to apply a splitter (1) that enables using two supplementary outlets (3) with the same spool valve. Operation of these outlets is selected by a solenoid valve (2) activated by a button on the lever of the spool valve. The line (4) conveys the oil of the low pressure circuit to pilot the spool in the splitter.

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Hydraulic systems - Hydraulic systems

9. The splitter spool pilot oil ( (1) , 18 ) comes from the low pressure via the tube (1) inserted on the spool valve of the gearbox. NOTE: The image shows the 24X24 version with 4 solenoid valves, the same applies to the remaining versions, 12X12 and 20X20.

WLAPL4S35CX19A

WLAPL4S35CX20A

WLAPL4S35CX21A

10. At the end of the turret of the spool valves there is a head (1) where a pipe (2) arrives from the ventral spool valve that contains the load sensing line.

11. The last user of the high pressure circuit is the ventral spool valve (1) . The pipe (3) is the outlet, (2) is the load sensing line that goes to the head ( (2) , 20 ), (3) comes from the base of the turret ( (3) , 13 ). The four outlets (5) must be fitted with the pressurized oil delivery / return quick couplers to control the implements.

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema , transmission general hydraulic system, 24X24 version (A) . - Spool valve turret base / EDC .

(20) . - Pressure switch 10 bar (145.00 psi) (10,19 Kg/cm2) creates the pressure, with the engine running and parking brake on, necessary for disengaging the trailer mechanical brake. (B) . - EDC unit (electronic lift). (21) . - High pressure pump. (C) . - Supplementary closed center spool valves. (22) . - Pressure regulating valve ( 190 - 195 bar (2755.00 - 2827.50 psi) (193,7 ÷ 198,8 Kg/cm²) , high pressure circuit. (D) . - Splitter. (23) . - Power steering / low pressure pump. (E) . - Spool valve turret head / EDC . (24) . - Intake filter. (F) . - Trailer brake valve. (25) . - Check valve, lets oil flow in one direction only. (G) . - Italian trailer braking version spool valve. (26) . - Power steering rotating spool valve ( orbitrol ). (H) .- Ventral spool valves. (27) . - Pressure regulating valve 260 bar (3770.00 psi) (265,12 Kg /cm2) power steering. (I) . - Gearbox spool valve. (28) . - Low pressure circuit delivery filter. (L) . - Services spool valve. (29) . - By-pass valve, opens with a pressure difference between the incoming oil and outgoing oil of 3.4 bar (49.30 psi) (3,46Kg/cm2) . If the filter is blocked, it allows the oil to flow, even if not filtered, so as not to ruin the services, and not remain with the machine stationary without any oil. (M) .- Power steering spool valve (orbitrol) . (30) . - Services and clutch engagement pressure regulating valve 18 bar (261.00 psi) (18,35 Kg/cm²) . (N) .- Intake filter and pump assembly. (31) . - By-pass valve, opens with a pressure difference between the hot oil and cold oil of 3.5 bar (50.75 psi) (3,57 Kg/cm2) . It allows the cold oil to flow and go to lubrication, on the contrary to the hot oil that will be diverted to the cooler. (O) .- Front and rear brakes circuit (32) . - Cooler, has the task of cooling the lubrication oil when it is too hot. (a) . - Trailer brake drive line (coming from the brake (33) . - Lubricating pressure regulating valve 2.9 - 3.7 bar pedals). (42.05 - 53.65 psi) (3 ÷ 3,8 kg/cm2) . (b) . - Splitter spool drive line (coming from the gearbox (34) . - Lubricating oil gearbox clutches, synchronizers spool valve). and shafts. (c) . - Load sensing line (joins the turret of the spool (35) . - Valve that regulates the quantity of oil lubricating valves / EDC and the ventral spool valves). the power take−off. It is driven by the pressure of the oil on the PTO clutch; with this engaged there will be greater lubrication, when it disengages the lubrication will be minimal and will concern the shaft and its rear bearing. (d) . - High pressure line. (36) - Bearings and PTO clutch lubrication. (e) . - Power steering supply line. (37) . - Clutch A solenoid valve. (f) . - Low pressure line. (38) . - Clutch B solenoid valve. (g) . - Lubrication line. (39) . - Clutch C solenoid valve. (h) . - Front brakes drive line (coming from the brake (40) . - Clutch D solenoid valve. pedals). (1) . - Pressure regulating valve 190 - 195 bar (2755.00 (41) . - Pressure switch 10 bar (145.00 psi) (10,2 - 2827.50 psi) (193,7 ÷ 198,8 Kg/cm²) , high pressure Kg/cm2) . It has the task of testing the low pressure oil circuit. pressure, if this falls under the setting the warning light on the dashboard will come on and signal low oil to the gearbox services. (2) . - Flow regulating valve. Driven by the load sensing (42) . - Oil temperature sensor on the gearbox spool line, it sends oil to the circuit services, EDC and spool valve. valves, if it is not required it is discharged.

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Hydraulic systems - Hydraulic systems

(3) . - Lifting solenoid valve.

(4) . - Cylinder safety valve 230 bar (3335.00 psi) (234,5 Kg/cm2) .

(5) . - Flow compensating valve.

(6) . - Lowering solenoid valve. (7) . - Bosch spool valve flow control. (8) . - Spool of spool valves Bosch (double acting and floating). (9) . - Splitter spool. (10) . - Splitter solenoid valve. (11) . - Spool of ventral spool valves (double acting and floating). (12) . - Directional valve, located in the load sensing circuit. In the case of two services with two different pressures, it has the task of making the flow regulating valve reach the greater pressure. If there is only one service, it has the function of directing the pressure towards the flow regulating valve and not onto another circuit service. (13) . - Pressure switch 10 bar (145.00 psi) (10,19 Kg/cm2): the warning light comes on, trailer brake engaged, on the dashboard when there is not enough pressure in the brake circuit to counter its mechanical parking brake. (14) . - Solenoid valve normally closed, prevents pressure discharge 10 bar (145.00 psi) (10,19 Kg/cm2) in the trailer brake circuit keeping it mechanically unbraked. (15) . - Solenoid valve normally open, allows oil to flow with a pressure greater than 10 bar (145.00 psi) (10,19 Kg/cm2) if you want to brake the trailer with the service brakes. (16) . - Trailer brake valve actuator / spool valve. (17) . - Flow regulating valve, if the service brake is operated it sends oil to the spool valve, on the contrary it diverts the oil onto the other circuit services. (18) . - Pilot valve, it has the task of operating the trailer brake valve when both service brakes are operated simultaneously. (19) . - Trailer brake circuit safety pressure switch 3 bar (43.50 psi) (3,05 Kg/cm2) , signals when there is not enough pressure in the circuit.

(43) . - Accumulator, capacity 0.70 l (0.18 US gal) at a maximum pressure of 60 bar (870.00 psi) (61,18 Kg/cm2) . It is used in order not to have oil pressure values that are too low during the exchange between one clutch and the other. (44) . - Clutch B pressure switch, calibrated to 3 bar (43.50 psi) (3,06 Kg/cm2) . If, with reverse drive engaged, the control unit does not see the pressure switch open (circuit under pressure), it disables the transmission and displays a fault code, the same thing if it sees both pressure switches open (44 and 45). (45) . - Clutch A pressure switch, calibrated to 3 bar (43.50 psi) (3,06 Kg/cm2) . If, with forward drive engaged, the control unit does not see the pressure switch open (circuit under pressure), it disables the transmission and displays a fault code, the same thing if it sees both pressure switches open (44 and 45). (46) . - Clutch A. (47) . - Clutch B. (48) . - Clutch C. (49) . - Clutch D. (50) . - PTO clutch. (51) . - Accumulator for gradual engagement of power take−off. It has the task of gradually applying the oil pressure on the clutch discs of the power take−off. (52) . - Brake for the power take−off clutch.

(53) . - Four wheel drive disengagement.

(54) . - Differential lock engagement

(55) . - Front-wheel drive disengagement solenoid valve.

(56) . - Differential lock solenoid valve. (57) . - PTO brake pressurized oil discharge spool on engaging the synchronized power take−off. (58) . - PTO brake and clutch solenoid valve.

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Hydraulic systems - Hydraulic systems

WLAPL4S35CX01J

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic systems - Hydraulic schema , transmission general hydraulic system, 24X24 version . . . . . . . . . . . . . . 11 Hydraulic systems - Static description power steering / low pressure, high pressure . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Hydraulic systems - 35 Hydraulic hand control - 355

T5.105 T5.115 T5.95

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Contents Hydraulic systems - 35 Hydraulic hand control - 355

SERVICE Hand control Adjust ventral spool valve control flexible cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - Hydraulic hand control

Hand control - Adjust ventral spool valve control flexible cables. 1.

When mounting the joystick (1) the flexible cables, the one with the yellow terminal (2) and the green one (3) , must be fitted keeping them parallel without crossing each other.

Lock the joystick in the neutral position by fully pressing the button (4) .

WLAPL4S35C705A

WLAPL4S35C706A

WLAPL4S35C707A

Unscrew the locknut (2) and raise the spacer (1) , connect the fork (3) , at the end of the cable, to the spool of the spool valve.

Move the spool valve near to the spacer (1) , without forcing it to prevent the spool of the spool valve from moving, then secure it with the screws (3) .

Using a wrench, keep the spacer stationary and tighten the locknut (2) .

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Index Hydraulic systems - 35 Hydraulic hand control - 355 Hand control - Adjust ventral spool valve control flexible cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - 35 Remote control valves - 204

T5.105 T5.115 T5.95

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Contents Hydraulic systems - 35 Remote control valves - 204

TECHNICAL DATA Remote control valve Closed center mechanical remote valve - General specification closed center auxiliary spool valves for remote controls (BOSCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Closed center mechanical remote valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Closed center mechanical remote valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Mid-mount remote control valve Closed center mechanical remote valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Closed center mechanical remote valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Remote control valve control lever Closed center mechanical remote valve - Dynamic description Ventral control valve joystick . . . . . . . . . 7

Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve 9 Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Closed center mechanical remote valve - Dynamic description Splitter Operation (if installed) . . . . . . . 17 Closed center mechanical remote valve - Overview Spool valve turret base components . . . . . . . . . . . 20 Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Dynamic description Connection between auxiliary control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Mid-mount remote control valve Closed center mechanical remote valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

SERVICE Remote control valve control lever Adjust spool valve control flexible cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Remote control valve Closed center mechanical remote valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Closed center mechanical remote valve - Assemble with the unit removed . . . . . . . . . . . . . . . . . . . . . . . . 46

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Closed center mechanical remote valve - Overhaul and connection plate assembly . . . . . . . . . . . . . . . . 47 Remove Bosch closed centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Couplers Service instruction QUICK COUPLER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

DIAGNOSTIC Couplers Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve General specification closed center auxiliary spool valves for remote controls (BOSCH) Location Method of operation Pressure relief valve setting Types of spool valves A) B) C)

Fitted in groups of 2 0 3 spool valves, fitted above the lift box. By means of a lever and flexible cable 190 - 195 bar (2755.00 - 2827.50 psi) Double-acting and floating, with flow control and lever retaining system. Double-acting and floating, with flow control and programmable lever retaining system. Double-acting and floating, with flow control and lever retaining system and splitter.

Remote control valve Closed center mechanical remote valve - Special tools List of specific tools required for the various operations 380000240 : Universal pressure testing kit.

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Torque

WLAPL4S35C301G

Part to tighten Nm (lbft) Pressure regulating valve adjuster screw (C1) 2.1 - 2.8 N·m (1.55 - 2.07 lb ft) Pressure regulating valve (C2) 13.5 - 14.2 N·m (9.96 - 10.47 lb ft) Turret base fitting (C3) 54 - 72 N·m (39.83 - 53.10 lb ft) Turret base fitting (C4) 16 - 21.3 N·m (11.80 - 15.71 lb ft) Quick couplers (C5) 60 - 66 N·m (44.25 - 48.68 lb ft) Turret base fitting (C6) 38 - 43 N·m (28.03 - 31.72 lb ft) Lever retaining screw (C7) 5.5 - 7.3 N·m (4.06 - 5.38 lb ft) Quick coupler assembly retaining screw (C8) 11 - 12 N·m (8.11 - 8.85 lb ft) Turret elements retaining nuts (C9) 25 - 28 N·m (18.44 - 20.65 lb ft) * For tightening the nuts for the 3 studs of the turret, follow the numbered sequence.

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kgm 0.21 to 0.28 kgm 1.34 to 1.44 kgm 5.50 to 7.34 kgm 1.63 to 2.17 kgm 6.11 to 6.73 kgm 3.87 to 4.38 kgm 0.55 to 0.74 kgm 1.12 to 1.22 kgm 2.54 to 2.85 kgm

Hydraulic systems - Remote control valves

Mid-mount remote control valve Closed center mechanical remote valve - General specification VENTRAL CONTROL VALVES Manufacturer Location Type: Method of operation

Walvoil Right-hand side of tractor near the cab bracket. A pack with two closed center spool valves. Double acting + float (with mechanical retainer in float) + double acting. By joystick located on the right-hand side of the operator

Mid-mount remote control valve Closed center mechanical remote valve - Torque PART TO TIGHTEN Plug (C1) Guard retaining screw (C2)

TIGHTENING TORQUE Kgm Nm(lbft) 24 N·m (17.70 lb ft) 2,44 Kgm 9.8 N·m (7.23 lb ft)

0,99 Kgm

WLAPL4S35C701B

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Remote control valve control lever Closed center mechanical remote valve - Dynamic description Ventral control valve joystick The ventral spool valves are governed by a joystick (1) on the operatorâ&#x20AC;&#x2122;s right-hand side.

WLAPL4S35C703A

WLAPL4S35C701A

The safety lock on the joystick has three positions: A. Fully out. All joystick movements available. B. Fully in. All joystick movements disabled. ATTENTION: To prevent accidental movement of the joystick when traveling on the public highway, put the safety lock into position (B) 2

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Hydraulic systems - Remote control valves

Joystick operation Pull the joystick rearwards to pressurize outlet (A1) of the spool valve in the lifting phase. Move the joystick forwards to pressurize outlet (B1) in the lowering phase. Further forward movement (F) of the joystick will select the floating position, connecting both outlets to the drain, which will allow a cylinder connected to the control valve to extend or retract freely. If the cylinder is fitted with an implement for working the land it can follow the surface of the land it is working. NOTE: When using the float position, pushing the joystick fully forward to overcome the resistance exerted by the return spring due to the double action. The lever will stay in that position thanks to a mechanical coupling in the cap of the spool valve, to make it go back bring it out of the coupling manually.

WLAPL4S35C702A

WLAPL4S35C704A

Moving the joystick to the left to pressurize outlet (A2) in the lowering phase, moving the joystick to the right to pressurize outlet (B2) in the lifting phase. On the front of the joystick there are two buttons (1) , when using implements, such as the front loader, they have the function of exciting two solenoid valves that double the function of each spool valve. In this way four movements are obtained with just two spool valves. ATTENTION: Do not hold the lever in the extension or retraction positions once the cylinder has reached its limit stop. This will cause the relief valve to â&#x20AC;&#x2DC;blowâ&#x20AC;&#x2122; which, if occurring over an extended period, may overheat the oil.

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Dynamic description and section view of auxiliary spool valve

WLAPL4S35C302G

(A) . - View of bottom of turret base. (B) . - View of turret left side.

(5) . - Flow control. (6) . - Pressure regulating valve 190 - 195 bar (2755.00 2827.50 psi) (193,7 Ăˇ 198,8 Kg/cmÂ˛) . (Ls) . - Load sensing line outlet for the ventral spool (7) . - Closing plate, when fitting trailer brake valve, it valves, if fitted. must be fitted in its place. (N) . - Pressurized oil outlet for the ventral spool valves, (8) . - Quick couplers. if fitted. (P) . - Oil inlet to the turret from the pump. (9) . - Double-acting, floating, spool valve with flow control and programmable lever retaining device. (T) . - Oil outlet from the turret to the outlet. (10) . - Double-acting, floating, spool valve with flow control, non-programmable lever retaining device and splitter. (1) . - Turret base. (11) . - Splitter mounting surface. 84568014 22/03/2013

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Hydraulic systems - Remote control valves

(2) . - Electronic lift spool valve. (3) . - Programmable lever retaining device. (4) . - Lever retaining device.

(12) . - Quick coupler assembly. (13) . - Spool valve operation flexible cable support.

Description and operation The auxiliary control valves serve for control of hydraulic loads external to the tractor. Up to a maximum of 3 auxiliary control valves can be fitted. The rear auxiliary spool valves are operated by the levers to the right of the operator. The levers and respective control valves are identified by color, i.e.: a lever in a specific color will operate the spool valve with the engagement half-coupling caps of the same color. Each control lever has three or four positions, depending on the type of control valve it operates. 1.. Lifting - Pull the lever towards the operator to extend the connected cylinder and lift the implement. 2.. Neutral - Push the lever away from the operator, leaving the lifting position, in order to select the neutral position and disconnect the connected cylinder. 3.. Lowering - Push the lever further away from the operator, beyond the neutral position, to return the cylinder and lower the implement. 4.. Float mode - Push the lever away from the operator, beyond the lowering position to select the "float" function. This will allow the cylinder to extend or return freely, permitting implements (such as blades) to follow the profile of the ground surface.

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Hydraulic systems - Remote control valves

Main hydraulic components within each auxiliary spool valve

SEZ35CAP3F-3

(1) . Flow control valve adjustment (2) . Flow Control Adjuster (3) . Load check valve

(4) . Spool (5) . Lock Valve (6) . Pin centering mechanism

Flow control valve adjustment ( (1) , 2 ) Flow control valve adjustment is carried out manually and controls the oil flow by means of the auxiliary spool valve. By turning the adjuster, the oil flow throttle clearance is varied by means of the flow control valve.

Flow control valve ( (2) , 2) The flow control valve reads the throttle pressure differential with the relative adjuster, and controls the flow by means of the auxiliary spool valve. As each flow control valve individually reads the pressure differential of the operating auxiliary spool valve, two or more circuits can be simultaneously controlled by working at different pressures.

Load check valve ( (3) , 2) The check valve impedes pressure backflow from the auxiliary spool valve circuit when the control pin is activated and the pump system pressure is less than the counterpressure in the circuit. The following example explains operation: When a cylinder is under a consistent load and the spool valve pin is moved from the neutral position to the lifting position, the pump pressure could be less than the counterpressure in the auxiliary spool valve circuit. In this event, the counterpressure would force the oil back into the circuit, momentarily reducing the load, before the pressure in the system increases to maintain and further lift the load. The load check valve prevents this from happening.

Lockout valve ( (5) , 2) The lockout valve is located in the auxiliary spool valve lifting duct and is closed when the valve is in neutral. 84568014 22/03/2013

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The valve prevents the implement from returning spontaneously, in the event of the pin grooves leaking when in the neutral position. The lockout valve opens automatically when the spool valve pin is moved from the neutral position.

Spool valve control pin ( (4) , 2) The spool valve control pin is kept centered in neutral; when it moves, it sends the flow of oil to the spool valve lifting or lowering orifices.

Pin centering and automatic release mechanism ( (6) , 2) The spring centering mechanism holds the spool valve pin in the neutral position. When the pin is moved to the lifting, lowering or float mode position, the mechanism holds the pin in position by means of two ball bearings that engage in a groove inside the control retainer. A pre-set release valve automatically releases the ball bearings, returning the pin to the neutral position each time the working pressure exceeds the predefined value.

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Hydraulic systems - Remote control valves

Flow control valve and check valve components

SEZ35CAP3F-4

(1) (2) (3) (4) (5) (6)

. . . . . .

Flow Control Adjuster Retainer Spring Spring guide Cap and seal Plastic cap

(7) . Retainer (8) . Plug (9) . Thrust washer. (10) . Seal (11) . Spring (12) . Check valve ball

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Hydraulic systems - Remote control valves

Spool

SEZ35CAP3F-5

(1) (2) (3) (4) (5) (6) (7)

. . . . . . .

End cap Seal Spacers Pin centering mechanism Pin Seal Seal

(8) . Spacer (9) . Thrust washer. (10) . Release pin (11) . Ball (12) . Piston (13) . Spring (14) . Spring cover

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Lockout valve components

SEZ35CAP3F-6

(1) (2) (3) (4)

. . . .

Piston Load check valve Ball Spring

(5) (6) (7) (8)

. . . .

Washer Spring Spring seat Spring centering

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Remote control valve Closed center mechanical remote valve Dynamic description Configurable Detent Operation (where fitted) A specific mechanical stop (detent) detains the lever in the chosen position of extension or retraction, until the auxiliary cylinder reaches the limit stop, allowing the implement to make the movement, without the need to hold the lever in position manually. In this way it is possible to perform other operations with both hands. When the set pressure is created in the hydraulic system, the control lever is automatically unhooked from the mechanical stop and moves back into neutral. The rotary control is used to select one of five detent settings. To select a setting, rotate the control until the number (2) on the end cap aligns with the mark (1) on the valve body. NOTE: If the number on the rotary control is not aligned correctly with the reference mark on the valve body, the performance of the valve may be affected. ATTENTION: Before turning the selector, ensure any residual pressure in the hydraulic system is exhausted. To do this, stop the tractor engine, cycle the remote valve lever through all positions and then place the lever in neutral. DCAPLT5NE010S6A

Each position offers the following functions: I. Raise (R), Neutral (N), Lower (L) and Float (F). Detent position in Float only. No lever auto return to neutral (kick out). II. Raise, Neutral and Lower positions only. No Float facility. No detent positions available. No lever auto return to neutral (kick out). III. Raise, Neutral, Lower and Float positions available. Detents in Raise, Lower and Float. Lever auto return to neutral (kick out) in Raise and Lower positions. IV. Raise, Neutral, Lower and Float positions available. Detents in Raise, Lower and Float. No lever auto return to neutral (kick out). V. Lower and Float positions available. Detents in Raise and Float. No lever auto return to neutral (kick out). To select position V., place the remote control valve lever in neutral, select position I or IV , then move the lever to the Float position. With the lever in Float select position V. To de-select position V , put the remote control valve lever into float, turn the selector control to position I or IV and then move the distributor lever into neutral. It is now possible to select positions I to IV . NOTE: When starting the machine's engine, make sure that the spool valve levers are in the correct position before operating the key switch. This prevents an attached implement from accidentally moving. Failure to observe these instructions can cause serious injury or death. With the selector in positions I to IV - Neutral With the selector in position V - Float

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Dynamic description Splitter Operation (if installed)

WLAPL4S35C303G

(A) . - Oil from spool valve quick coupler. (B) . - Oil from spool valve quick coupler. (C) . - Splitter supplementary quick coupler oil. (D) . - Splitter supplementary quick coupler oil. (E) . - Splitter quick coupler oil. (F) . - Splitter quick coupler oil. (T) . - oil to the outlet. (X) . - Splitter spool pilot oil, coming from the gearbox spool valve.

(1) . (2) . (3) . (4) . (5) . (6) . (7) . (8) .

- Splitter spool compartment caps. - Spool positioning spring. - Splitter spool. - Spool piloting line check valve. - Splitter main quick couplers. - Splitter solenoid valve. - Supplementary main quick couplers. - Splitter body.

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Hydraulic systems - Remote control valves

WLAPL4S35C304G

: Discharge oil. : Oil at static rest. : Pressurized oil. : Oil at the pilot pressure from the gearbox spool valve. (A) . - Oil from spool valve quick coupler. (B) . - Oil from spool valve quick coupler. (C) . - Splitter supplementary quick coupler oil. (D) . - Splitter supplementary quick coupler oil. (E) . - Splitter quick coupler oil.

(F) . (1) . (2) . (3) .

- Splitter quick coupler oil. -Splitter hydraulic diagram. - Splitter with solenoid valve energized. - Splitter with solenoid valve at rest.

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Hydraulic systems - Remote control valves

1. If you want to use the splitter to take advantage of two supplementary quick couplers, press the button (2) of the lever (1) , then, simultaneously, operate the lever.

WLAPL4S35C301A

WLAPL4S35CX19A

2. Make reference 2 situation 2. The oil coming from the gearbox spool valve through the pipe (1) enters the splitter and, via the excited solenoid valve, goes on to the spool and moves this onto the left diverting the oil coming from the supplementary spool valve ( (A) and (B) , 2 ) on the supplementary outlet ( (C) and (D) , 2 ). 3. If you want to use the spool valve without operating the button ( (1) , 3 ), the spool will remain 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 spool valve ( (A) and (B) , 2 ) will be diverted onto the supplementary outlets ( (E) and (F) , 2 ).

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Overview Spool valve turret base components

WLAPL4S35C305G

(A) - Compartment for the flow regulating valve assembly (3) . - Pressure relief valve, set to 190 - 195 bar (2755.00 and housing. - 2827.50 psi) (193,7 Ăˇ 198,8 Kg/cmÂ˛) . (B) - Pressurized oil inlet from the pump. (4) . - Check valves on the load sensing between each element of the turret ensure that the highest load sensing pressure in the circuit is transmitted to the flow regulation valve to regulate the feed. (1) . - Flow regulating valve spool. (5) . - Spring for check valve. (2) . - Flow regulating valve spring, keeps the spool in (6) . - Gasket. such a condition as to divert the oil to the outfeed. The load, of the spring, is contrasted by the pilot pressure of the load sensing circuit coming from the service that is working, spool valves and EDC , that by moving the spool closes the outlet and opens the orifice for delivery to the service. 84568014 22/03/2013

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Hydraulic systems - Remote control valves

(7) . - Gasket anti-extrusion ring.

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Remote control valve Closed center mechanical remote valve Dynamic description

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Hydraulic systems - Remote control valves

SEZ35CAP3H-1

LIFTING OIL FLOW: Auxiliary control valve operation - Lifting (cylinder extension)

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Hydraulic systems - Remote control valves

: Pressurized oil : Auxiliary control valve working pressure : Discharge oil (1). (2). (3). (4). (5). (6).

Flow control valve adjuster Metering Land Flow regulator Load check valve Control pin Roll Pin

(7). Lock Valve (8). Lifting duct (cylinder extension) (9). Lowering duct (cylinder retraction) (10). Centering pin and release mechanism (11). Manually adjusted flow rate throttle

When the control valve lever is moved to the lifting position, the control pin (5) moves to the left allowing the spring balls to engage in the groove on the left-hand side of the automatic release mechanism (10). By moving the pin to the lifting position, the peg (6) on the lockout valve (7) will rise on the pin and hold the valve in the open position. Duct (B) is now connected to duct (C) and duct (E) is connected to duct (F). The flow from duct (C) is stopped by the ball (4) on the check valve until the pressure in the duct can lift the ball in its seat, countering the pressure in duct (E) in the lifting duct. Oil can flow from: In duct (C), through the check valve and to duct (E). Along the flat part of the control pin and to duct (F). Through the lock valve (7). On the outside, through the lifting duct (8) of the auxiliary control valve. The oil from the extended cylinder returns through the lowering duct and duct (H), around the control pin groove and flows to the reservoir through shared duct (G). If the check valve (4) is not installed, the pump pressure may be unable to support the load in the lifting duct when the auxiliary control valve is moved from neutral to the lifting position. In this event, the load will momentarily lower until the pressure in the pump can sustain it. The quantity of oil that flows through the auxiliary control valve is controlled by the flow rate manual adjustment knob (1), which manually alters the throttle clearance (11). To maintain a constant flow rate in the auxiliary control valves when the pressure varies at the parallel duct pump in feed (A), the flow control valve reads the pressure difference at the throttle (11), manually adjusted between ducts (A) and (B). The difference in pressure at each end of the pin makes it move to re-balance and continuously controls the flow rate on the pin grooves (2) in order to maintain a constant flow rate through the throttle (11), regardless of the pressure in the other hydraulic circuits. The pressure in duct (C) is also directed to load sensing duct (D) and the flow rate compensating valve.

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Dynamic description LOWERING OIL FLOW (cylinder retraction)

SEZ35CAP3F-8

Auxiliary control valve operation - Lowering (cylinder retraction) : Pressurized oil : Auxiliary control valve working pressure : Discharge oil (1). (2). (3). (4). (5). (6).

Flow control valve adjuster Metering Land Flow regulator Load Check Control pin Roll Pin

(7). Lock Valve (8). Lifting duct (cylinder extension) (9). Lowering duct (cylinder retraction) (10). Centering pin and release mechanism (11). Manually adjusted flow rate throttle

When the control valve lever is moved to the lowering position, the control pin (5) moves to the right, allowing the spring balls to engage in the central groove on the automatic release mechanism (10). As with the lifting cycle, the position of the pin allows the lockout valve (7) pin (6) to maintain the valve in the open position. Duct (B) is now connected to duct (C) and duct (E) is connected to duct (H). The oil from the parallel duct (A) is directed through the flow control valve and the throttle (2) and then to ducts (B), (C) and to load sensing duct (D). The ball (4) on the check valve of the load stays closed until the pump system pressure in the duct can overcome the back pressure in duct (E). When the ball on the check valve lifts, the oil flows to duct (E), around the control pin, to duct (H) and is directed out through the lowering duct on the auxiliary control valve.

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Hydraulic systems - Remote control valves

The oil from the retracted cylinder flows to duct (G) and returns to the reservoir through the lifting duct and the lockout valve (7). The flow rate through the auxiliary control valves is controlled in the same way in the â&#x20AC;&#x2122;Lifting oil flowâ&#x20AC;&#x2122; heading, i.e: reading the pressure difference inside the manually adjusted throttle (11).

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Dynamic description OIL FLOW IN NEUTRAL

SEZ35CAP3F-9

Auxiliary control valve operation - Neutral : Pressurized oil : Oil at static rest : Discharge oil (1). (2). (3). (4). (5). (6).

Flow control valve adjuster Metering Land Flow regulator Load Check Control pin Roll Pin

(7). Lock Valve (8). Lifting duct (cylinder extension) (9). Lowering duct (cylinder retraction) (10). Centering pin and release mechanism (11). Manually adjusted flow rate throttle

When the auxiliary control valves are in neutral, the control pin (5) is held in the central position by the centering spring. The oil flow from the parallel duct (A) to the lifting and lowering ducts is stopped by the control pin grooves. Duct (C) and load sensing duct (D) out feed to the reservoir through duct (G). The ducts to the lifting and lowering ducts are stopped by the control pin grooves (5). The lockout valve pin (7) is inserted in the restriction on pin (5), keeping the valve in the closed position with the spring, to prevent an extended cylinder from retracting under load in the event of slight losses from the control pin.

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Dynamic description FLOAT MODE OIL FLOW

SEZ35CAP3F-10

Auxiliary control valve operation -- Float mode : Pressurised oil : Outlet oil (1). (2). (3). (4). (5). (6).

Flow control valve adjuster Metering Land Flow regulator Load Check Control pin Roll Pin

(7). Lock Valve (8). Lifting duct (cylinder extension) (9). Lowering duct (cylinder retraction) (10). Centering pin and locking mechanism (11). Manually adjusted flow rate throttle

The float mode position allows the oil to flow from both the lifting duct and the lowering duct on the auxiliary control valve, permitting the cylinders to extend or retract freely. This is particularly useful for implements such as leveller blades, allowing them to â&#x20AC;?floatâ&#x20AC;? whilst following the profile of the ground surface. When the control valve lever is pushed fully forwards to the float mode position, the control pin (5) moves fully to the right allowing the spring balls (10) to engage in the groove on the right hand side of the automatic release mechanism. The oil flow from duct (B) to the lifting and lowering ducts is stopped by the pin grooves. As a result of the position of the pin, the lockout valve (7) pin (6) keeps the valve in the open position. The auxiliary control valve lifting and lowering ducts are connected to duct (G) on the reservoir, allowing the oil to flow freely from one duct on the cylinder to the other. If there is a vacuum in the circuit, the oil is sucked from one end of the cylinder to the other.

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Dynamic description AUTOMATIC RELEASE PRESSURE REGULATING VALVE OPERATION

SEZ35CAP3F-11

Automatic release pressure regulating valve operation : Auxiliary control valve pressure at 175 bar (2537.50 psi). : Outlet oil (1). (2). (3). (4).

Centering pin and automatic release mechanism Radial ducts Control pin Ball

(5). (6). (7). (8).

Stop piston Pre--loaded spring piston Stop balls Centralising Spring

Under normal working conditions, the auxiliary circuits are protected from excess pressure by the release pressure control valve, which moves the control pin to neutral when the working pressure of the cylinder exceeds the pre-set value. If the auxiliary control valve lever is kept stationary by the operator to prevent the pin (3) going back to neutral, the maximum working pressure is limited to a maximum of 195 bar (2827.50 psi) by the pressure compensating valve in the hydraulic pump. The operation of the release adjustment valve is as follows: When the control valve pin is moved to the lifting or lowering position, the centering pin and automatic release mechanism retaining balls (1) are locked by the conical part of the spring piston. When lifting or lowering, the working pressure of the auxiliary control valve circuit is also detected in the central hole of the pin through the small radial orifices (2). As the pressure increases, the force applied on the smallest ball (4) on the end of the pin (3) pushes the automatic release control valve piston (5) and the spring piston (6) to the left. When the automatic release pressure ( 175 bar (2537.50 psi)) is reached, the centering mechanism balls are no longer held by the conical part of the pre-loaded piston, and the centering spring (8) moves the pin to neutral. 84568014 22/03/2013

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Hydraulic systems - Remote control valves

Remote control valve - Dynamic description Connection between auxiliary control valves

WLAPL4S35C301H

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Hydraulic systems - Remote control valves

(Ls) . - Load sensing circuit outlet, if auxiliary ventral control valves are mounted. (N) . - Pressurized oil outlet to auxiliary ventral control valves, where mounted. (P) . - Oil inlet from pump. (1) . - Turret base. (2) . - Electronic lift spool control valve. (3) . - Double-effect control valve, float mode, flow rate controller and with adjustable lever retaining device. (4) . - Double-effect control valve, float mode, flow rate controller, with lever retaining device and distributor splitter. (5) . - Turret head. All elements on the control valves use the same in feed and return to reservoir duct, positioned in parallel. The load sensing duct passes through the center of the control valve unit. The parallel ducts and load sensing system allows two or more control valves to be used simultaneously, with no loss of efficiency. The seals (1) and the check valves on the load sensor (2) fitted between each element, ensure that the highest load sensing pressure in the circuit is directed to the flow adjustment valve to control the supply

SEZ35CAP3A-17

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Dynamic description OPERATION OF TWO OR MORE AUXILIARY CONTROL VALVES SIMULTANEOUSLY Operation with a single auxiliary control valve

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Hydraulic systems - Remote control valves

SEZ35CAP3K-2

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Hydraulic systems - Remote control valves

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Hydraulic systems - Remote control valves

: Pressurized oil : Auxiliary control valve working pressure : Discharge oil : Oil at static rest (A). Auxiliary control valve operating (1). Parallel duct (connecting the auxiliary control valve elements) (2). Load sensing line (connecting the auxiliary control valve elements) (3). Manual flow rate limiter

(B). Remote Valves in Neutral (4). Metering Lands (5). Flow regulator (6). Load sensing line check valve

Operation with two auxiliary control valves

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Hydraulic systems - Remote control valves

SEZ35CAP3K-1

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Hydraulic systems - Remote control valves

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Hydraulic systems - Remote control valves

: Pressurized oil : Auxiliary control valve operation at high pressure : Auxiliary control valve operation at lower pressure : Discharge oil (A). Auxiliary control valve operating at high pressure (1). Parallel duct (connecting the auxiliary control valve elements) (2). Load sensing line (connecting the auxiliary control valve elements) (3). Manual flow rate limiter

(B). Auxiliary control valve operating at low pressure (4). Metering Lands (5). Flow regulator (6). Load sensing line check valve

Description and operation As the auxiliary control valves are provided with a shared parallel inlet duct and individual flow rate control valves, two or more auxiliary control valves can operate at the same time, with no loss of efficiency. This is carried out by the flow rate adjusters, which regulate the flow through each auxiliary control valve, regardless of the pump pressure. If theses valves were not fitted and two auxiliary control valves worked at the same time at different pressures, the oil would tend to flow to the circuit with the lighter load. There follows a detailed explanation of single auxiliary control valve operation and combined operation with another auxiliary control valve. When only one auxiliary control valve is used, the pressure in the parallel duct is the same as the pump pressure. The auxiliary control valve flow rate is set by the flow rate adjusting knob, controlling the limiter clearance (3). The limiter pressure differential (3) is taken at each end of the flow rate control pin (5), which moves to a balanced position to dose the flow rate on the grooves (4). Control of the flow rate on the grooves (4) produces a constant flow rate through the flow rate manual limiter (3) and through the auxiliary control valve. It is essential that oil flow is controlled singularly through two or more auxiliary control valves, working simultaneously at different pressures, otherwise the oil will tend to flow towards the circuit with lower pressure. When using two or more hydraulic services, the working pressure in the parallel duct is at the maximum value of the hydraulic system, as read through load sensing line.

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Hydraulic systems - Remote control valves

Mid-mount remote control valve Closed center mechanical remote valve - Overview

WLAPL4S35C702F

WLAPL4S35C701F

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Hydraulic systems - Remote control valves

Legend : pilot oil, pilots the flow regulating valve on the basis of the turret of the spool valves : Oil under pressure coming from the pump via the flow regulating valve : Discharge oil : Oil at static rest (1) - Discharge oil port.

(8) - Double acting spool valve + float with mechanical catch in float. (2) - Port B2 double-acting spool valve. (9) - Feed oil port. (3) - Port A2 double-acting spool valve. (10) - Double-acting spool valve spool. (4) - Port A1 double-acting spool valve + float. (11) - Double acting spool valve spool + float with mechanical catch in float. (5) - Port B1 double-acting spool valve + float. (12) - Check valves set between the two piloting pressures coming from the two spool valves, ensures that the higher load sensing pressure, in the case of two spool valves in action, is transmitted to the flow regulation valve to control the feed. (6) - Piloting oil port, has the function of piloting the flow (13) - Restrictor blows by a quantity of oil equal to 3 l/min regulating valve that will send oil to the spool valve only (0.79 US gpm). if this is engaged. (7) - Double-acting spool valve. (14) - Check valve.

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Hydraulic systems - Remote control valves

Remote control valve control lever - Adjust spool valve control flexible cables. 1.

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 AUXILIARY CONTROL VALVES (with the unit removed) 1.

Remove the seal (1) and the load sensing check valve (2).

SEZ35CAP3A-17

SEZ35CAP3A-18

SEZ35CAP3A-16

Remove the threaded parts on the ends and extract the flow adjuster (2) from the valve body. Auxiliary control valve components

Flow control valve adjustment

Flow Control Adjuster

Load check valve

Control pin

Lock Valve

Pin centering mechanism

Remove the control pin (1).

NOTE: Before removing the pin, make sure that the flat sides (1) at the end of the pin are in the vertical position, as shown. If necessary, rotate the pin but do not use force as this may damage the pin and the lock valve pin (5).

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Hydraulic systems - Remote control valves

Remove the lock valve from the lifting duct as follows: Using a small screwdriver, open the two slots (1) on the retaining device (2) and rotate through 90 Â° . Remove the spring seat (3) from the housing. Remove the lock valve and piston.

SEZ35CAP3A-19

SEZ35CAP3A-20

SEZ35CAP3A-21

SEZ35CAP3A-22

Remove in succession: retaining device (8), spring seat (7), spring (6), washer (5), spring (4), ball (3), lock valve (2) and piston (1).

Carefully remove the flow control plug.

ATTENTION: Take care when removing the plug as it is under the pressure of spring (1).

Remove in succession: plug (5) with seal, spring guide (4), spring (3), retainer (2) and flow control valve (1).

Then disassemble the lock valve removing the guard (6), retainer (7), plug (8), ring (9), gasket (10), spring (11) and ball (12).

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Hydraulic systems - Remote control valves

SEZ35CAP3F-5

Control pin (1). (2). (3). (4). (5). (6). (7).

End cap Seal Shim Pin centering mechanism Pin Seal Seal

(8). Spacer (9). Thrust washer (10). Release pin (11). Ball (12). Piston (13). Spring (14). Spring cover

Remove the control pin by unscrewing the centering mechanism. Do not disassemble the mechanism.

10.

The release pin is at the centre of the pin (5). It is a pre-set mechanism which only requires washing with an approved degreasing product, without removing the release pin (10).

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Assemble with the unit removed 1.

For assembly operations, follow the disassembly operations ( Remote control valve Closed center mechanical remote valve - Disassemble (35.204)) in reverse order. Remember to fit the lock valve before the control pin.

Before inserting the control pin in its seat, make sure that the flat sides (1) at the end of the pin are in an upright position, as in the figure. DO NOT rotate the pin once inserted in the seat, this would damage the pin and the lock valve piston.

SEZ35CAP3A-2

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Overhaul and connection plate assembly 1.

Unscrew the closing cap (1).

SEZ35CAP3A-4

SEZ35CAP3A-23

SEZ35CAP3A-24

SEZ35CAP3A-3

Remove the plug (1) and the piston (2).

Remove the adjustment shims (3).

Extract the pin (1) and spring (2).

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Hydraulic systems - Remote control valves

Assembly 1.

For assembly operations, follow the previously described disassembly operations in reverse order.

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Hydraulic systems - Remote control valves

Remote control valve - Remove Bosch closed centre To remove the auxiliary spool valve assembly, proceed as follows: 1.

Lower the hydraulic arms.

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

WLAPL4S90C123A

MOIL12APL0060AA

Detach the spool piloting (1) and outlet (2) diverter pipes. Detach the feed pipe from the pump to the spool valve assembly (3) and the one to the ventral spool valves (4) (where applicable). If present, disconnect the connection pipe from the trailer brake valve to the Italian spool valve (5) and the electrical connector connected to the pressure sensor on the trailer brake valve.

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Hydraulic systems - Remote control valves

Detach the control tie-rods (1) from the spool valve levers.

WLAPL4S90C123A

MOIL12APL0061AA

MOIL12APL0029AA

MOIL12APL0030AA

Using a suitable hoist, support the auxiliary spool valves unit, take out the retaining bolts (1) and extract the unit from the tractor. Set the unit on a workbench.

Remove the retaining bolts (1) and detach the quick coupler block diverter.

Take out the retaining bolts and detach the valve support block diverter (1) and the quick coupler supports of the lower spool valves (2).

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Hydraulic systems - Remote control valves

10.

If present, detach the trailer brake valve (1), detach the spool valve control levers (2) from the block, then detach the fastening bracket (3) on the rear

MOIL12APL0031AA

MOIL12APL0032AA

Take off the tightening nuts (1) of the spool valve elements and remove the top closing plate. Number or mark the various spool valve plates before removal.

11.

Extract the first auxiliary spool valve (1).

12.

Extract the second auxiliary spool valve (2).

13.

Extract the third auxiliary spool valve (3).

14.

Extract the electronic lift control spool valve (4).

15.

If necessary, remove the threaded tie-rods (5) from the connecting plate (6).

MOIL12APL0033AA

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Hydraulic systems - Remote control valves

Remote control valve - Install To refit the auxiliary spool valves, proceed as follows: 1.

Before reassembling, clean and degrease the mating surfaces.

Respect the tightening torques prescribed on page Remote control valve Closed center mechanical remote valve - Torque (35.204)

For the orientation of the various components, refer to the illustration Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) and Remote control valve Closed center mechanical remote valve - Dynamic description Splitter Operation (if installed) (35.204)

Tighten the turret element tightening nuts to the right torque and in the sequence described Remote control valve Closed center mechanical remote valve - Torque (35.204)

Make sure that the seal and check valve are correctly seated.

Install the spool valves in their original order following the indications affixed during removal.

Position the end plate.

Refit the rear locking bracket and the spool valve control levers.

Mount the supports of the quick couplers on the spool valve.

10.

Where applicable, fit the trailer brake valve, diverter block and relevant support.

11.

Using appropriate lifting equipment, set the spool valve assembly back on the machine and position the fixing screws.

12.

Connect the feed pipe from the pump and the feed pipe to the ventral spool valves, where applicable. Where applicable, connect the connectors to the pressure sensor on the trailer brake valve and the pipe to the Italian trailer brake valve. Connect also the two pipes going to the brakes.

13.

Where applicable, connect the spool piloting pipe and outlet pipe to the diverter assembly.

14.

Connect the load sensing piloting pipe.

15.

Connect the connectors on the solenoids of the electronic lift spool valve and the oil recovery pipes from the quick couplers.

16.

Connect the flexible cables for spool valve control and adjustment them according to Remote control valve control lever - Adjust spool valve control flexible cables. (35.204)

17.

Connect the battery negative cable, put the cover back on and lower the right-hand steps.

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Hydraulic systems - Remote control valves

Remote control valve - Install NOTICE: before and after carrying out the operations described here below, always check that the relative hydraulic connection fittings are connected properly.

Instructions for the connection of hydraulic pipes â&#x20AC;&#x153;Diverterâ&#x20AC;? 1.

Check that the plastic assembly clip (1) is located in the groove and that the plastic release ring (2) moves freely in its seat.

Push the male fitting into the female fitting until the assembly clip (1) seats up against the female fitting.

At this point the connection is secure and cannot come loose.

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MOIL13TR00918AA

MOIL13TR00919AA

Hydraulic systems - Remote control valves

Instructions for the disconnection of hydraulic pipes â&#x20AC;&#x153;Diverterâ&#x20AC;? 1.

Using a screwdriver, prise the assembly clip (1) from its seat and push the male fitting fully into the female fitting as far as it will go.

MOIL13TR00920AA

MOIL13TR00921AA

With a firm, sharp movement, pull the male from the female fitting.

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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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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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Couplers - Troubleshooting Problem Engagement impossible.

Possible Cause The male coupler is not compatible. Dirt or soil in the female coupling.

Difficult engagement.

Dirt or soil in the female coupling.

Oil leakage from the female coupling after disengagement of the male connector.

Dirt or soil in the female coupling.

Oil leakage from the female coupling after disengagement or engagement of the male connector.

Valve gasket damaged. Internal gaskets damaged

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Correction Replace the male connection. Spray solvent inside and outside the female pressure tap (see Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) figure 1 . Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) figure 2), wait for a few seconds for the solvent to react. Perform some hooking/unhooking operations (see Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) figure 3) and if necessary do the cleaning again to make the coupling fluid. Spray solvent inside and outside the female pressure point (see Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) figure 1. Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) figure 2), wait for a few seconds for the solvent to react. Perform some hooking/ unhooking operations (see Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) figure 3) and if necessary do the cleaning again to make the coupling fluid. Spray solvent inside and outside the female pressure tap (see Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) figure 1, Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) figure 2 ) and wait a few seconds for the solvent to react. Perform some hooking/unhooking operations (see Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) figure 3) and if necessary do the cleaning again to make the coupling fluid. Replace. Replace.

Hydraulic systems - Remote control valves

Problem Oil leakage from the couplings after engagement

Possible Cause Dirt or soil in the seal area.

Gasket damaged.

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Correction Spray solvent inside and outside the female pressure tap (see Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) figure 1, Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) figure 2 ) and wait a few seconds for the solvent to react. Perform some hooking/unhooking operations (see Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) figure 3) and if necessary do the cleaning again to make the coupling fluid. Disconnect the connectors, replace the damaged gasket and, if necessary, the anti-extrusion ring.

Index Hydraulic systems - 35 Remote control valves - 204 Couplers - Service instruction QUICK COUPLER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Couplers - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Mid-mount remote control valve Closed center mechanical remote valve - General specification . . . . . . . . . . . . . . 6 Mid-mount remote control valve Closed center mechanical remote valve - Overview . . . . . . . . . . . . . . . . . . . . . . . 40 Mid-mount remote control valve Closed center mechanical remote valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remote control valve - Dynamic description Connection between auxiliary control valves . . . . . . . . . . . . . . . . . . . 30 Remote control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Remote control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Remote control valve - Remove Bosch closed centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Remote control valve Closed center mechanical remote valve - Assemble with the unit removed . . . . . . . . . . . . 46 Remote control valve Closed center mechanical remote valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Remote control valve Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . 16 Remote control valve Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . 22 Remote control valve Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . 25 Remote control valve Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . 27 Remote control valve Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . 28 Remote control valve Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . 29 Remote control valve Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . 32 Remote control valve Closed center mechanical remote valve - Dynamic description Splitter Operation (if installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remote control valve Closed center mechanical remote valve - General specification closed center auxiliary spool valves for remote controls (BOSCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remote control valve Closed center mechanical remote valve - Overhaul and connection plate assembly . . . . . 47 Remote control valve Closed center mechanical remote valve - Overview Spool valve turret base components 20 Remote control valve Closed center mechanical remote valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remote control valve Closed center mechanical remote valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remote control valve control lever - Adjust spool valve control flexible cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Remote control valve control lever Closed center mechanical remote valve - Dynamic description Ventral control valve joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Hydraulic systems - 35 Three-point hitch control valve - 114

T5.105 T5.115 T5.95

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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 the hydraulic lift control spool 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 the hydraulic lift control spool valve Components of the EDC control spool valve

WLAPL4S35C604G

(1) . (2) . (3) . (4) .

Load check valve Lift cylinder relief valve 230 bar (3335.00 psi) 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

operation The main components of the electronically controlled hydraulic lift system are:

Flow Control Spool This spool regulates the flow of oil coming from the parallel gallery that goes through the center of the control spool valve EDC and is directed to the hydraulic lift. The valve compares the pressure in the parallel gallery with the working pressure of the hydraulic lift and regulates the delivery to the lift circuit according to the requirements of the lift.

Raise spool The raise spool sends oil to the lift circuit and is controlled directly by the relevant modulating solenoid valve.

Raise solenoid valve The raise solenoid valve is the modulating type controlled by the microprocessor of the electronically controlled hydraulic lift that modulates its activation in proportion to the requested lifting speed.

Load check valve The load check valve avoids the static oil in the lifting cylinder from returning to the tank. This valve is opened only when the pressure in the lifting spool exceeds that of the static oil in the lifting cylinder.

Lift Cylinder Relief Valve This valve protects the lifting cylinder from peaks in load (water hammering) and comes into operation at 230 bar (3335.00 psi).

Lowering solenoid valve The lowering solenoid valve has the same executive configuration as the modulating lifting solenoid valve. It too is activated by the microprocessor and controls the operation of the lowering dosing valve to maintain the desired drop rate of the implement.

Lowering dosing valve The lowering dosing valve regulates the quantity of flow out from the lifting cylinder towards the tank during hydraulic lift lowering. It is actuated by the relevant modulating solenoid valve.

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Hydraulic systems - Three-point hitch control valve

Neutral position NOTE: the hydraulic lift cylinder is the single-acting type and as a result has only one connection for lifting and lowering the lift arms. When the hydraulic lift is in the neutral position, the control solenoid valves are de-energized. The oil flows from the parallel gallery (A) through the flow compensating spool and then in the gallery (B), where it remains blocked by the collars of the lifting spool. Oil under pressure in the hydraulic lift circuit is prevented from entering gallery â&#x20AC;&#x2DC; (E) â&#x20AC;&#x2122; by the load check valve (5) The pressurized static oil contained in the lift circuit acts on the right side of the dosing valve, via the calibrated orifice (X). The pressure applied in this way keeps the dosing valve in the closed position, preventing the oil coming from the gallery (E) from returning to the tank via the gallery (F). When the spool valve is in the neutral position, the gallery (C) and the galleries (D) for load sensing are connected to the tank via the central section of the lifting spool and the gallery (F). Gallery (G) is a common return to the reservoir running through the center of the spool valve stack.

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Hydraulic systems - Three-point hitch control valve

WLAPL4S35C605G

: Pump delivery : Oil at static rest : Return to Reservoir (1) (2) (3) (4)

. . . .

Raise solenoid valve Raise spool Flow compensating spool Load check valve

(5) . Lift cylinder safety valve 230 bar (3335.00 psi) (6) . Lowering dosing valve (7) . Lowering solenoid valve

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Hydraulic systems - Three-point hitch control valve

Lifting When the hydraulic lift is raised with the operator controls, or when the electronic control system automatically reduces the working depth of the implement, the microprocessor excites the modulating raise solenoid valve. The controlled excitation of the solenoid valve by the microprocessor allows the solenoid valve to move the spool to the right in proportion to the raise percentage requested by the system. When the pressure in the system is sufficient to raise the check valve (5) from its seat, the oil flows from the gallery (C) to the gallery (E) and operates the lifting cylinder. The pressure of the oil in the circuit works on the right-hand side of the dosing valve (H) through the calibrated orifice (X), keeping the valve in the closed position and preventing the oil in the gallery (E) from returning to the tank via the gallery (F) . The working pressure of the cylinder of the hydraulic lift is detected in the gallery (C) and in the load sensing gallery (D), that regulates the delivery of the hydraulic pump. See Remote control valve Closed center mechanical remote valve - Dynamic description and section view of auxiliary spool valve (35.204) "Auxiliary spool valves in closed center" for further details on the operation of the load sensing circuit. The pressure in the gallery (C) contrasts the action of the spring on the right-hand end of the flow control spool while, simultaneously, the system pressure in the gallery (B) acts on the left end of the spool. The pressure differential at the two ends of the flow control spool moves this spool to find a state of balance, automatically regulating the oil flow through the parallel gallery (A)on the dosing collars (Y) and through the gallery (C) and (E), to reach the lifting cylinder. The flow control spool is essential to ensure that the flow coming from the parallel gallery (A) and directed to the hydraulic lift is dosed precisely, independently of the working pressure of any auxiliary spool valves operating at the same time as the hydraulic lift. When the lift arms reach the required height, the microprocessor interrupts the signal that goes to the solenoid valve and the lifting spool is moved to the left by the spring, returning to the neutral position. If the lift arms are subjected to peaks in load (water hammering) and the pressure in the circuit of the hydraulic lift exceeds 200 bar (2900.00 psi) , the safety (relief) valve of the lifting cylinder vents the excess pressure in the tank. The Figure 3 shows the flow of oil in the flow control spool when the circuit of the hydraulic lift is the one that operates at the highest pressure of the whole system. The Figure 4 shows the operation of the flow control spool when the hydraulic lift works at a lower pressure but simultaneously with an auxiliary spool valve that operates at a greater pressure. In this situation, the system pressure in the parallel gallery (A) is greater than the working pressure of the hydraulic lift.

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Hydraulic systems - Three-point hitch control valve

Spool Valve EDC â&#x20AC;&#x201C; Lifting (lifting at high pressure)

WLAPL4S35C606G

: Pump pressure oil : Return to Reservoir (1) (2) (3) (4)

. . . .

Raise solenoid valve Raise spool Flow compensating spool Load check valve

(5) . Lift cylinder safety valve (6) . Lowering dosing valve (7) . Lowering solenoid valve

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Hydraulic systems - Three-point hitch control valve

Spool Valve EDC â&#x20AC;&#x201C; Lifting Lifting at low pressure simultaneously with auxiliary spool valves operating at a higher pressure

WLAPL4S35C607G

: Pump pressure oil : Hydraulic lift pressure (lower than the pump pressure) : Return to Reservoir (1) (2) (3) (4)

. . . .

Dosing valve Flow Compensating Spool Raise spool Raise solenoid valve

(5) . Load check valve (6) . Lift Cylinder Safety Valve (7) . Lowering solenoid valve

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Hydraulic systems - Three-point hitch control valve

Lowering The hydraulic lift arms are lowered by discharging the oil contained in the cylinder of the hydraulic lift into the reservoir in a controlled manner via the lowering dosing valve.

Lowering dosing valve 1. Sleeve 2. Dosing spool 3. Pilot spool 4. Plug 5. Circlip WLAPL4S35C613A

WLAPL4S35C614A

WLAPL4S35C615A

The lowering cycle comprises: The modulating solenoid valve is excited and the piston (1) moves the pilot spool (6) to the right. The oil trapped on the right hand end of the lowering valve (H) is now control vented over the lands of the pilot spool (2) to the reservoir through gallery (F). The pressure of the oil contained in the gallery (E) of the lifting cylinder acts on the beveled side (4) of the dosing spool (3) , moving the latter to the right.

The oil coming from the lifting cylinder flows along the dosing collars (5) of the valve and returns to the tank, allowing the arms to lower by gravity under the weight of the implement. The drop rate is controlled electronically by the microprocessor and by the modulating lowering solenoid valve, that regulates the clearance above the dosing collars (5)

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Hydraulic systems - Three-point hitch control valve

Spool Valve EDC - Lowering (1)

WLAPL4S35C608G

: Pump pressure oil : Oil at static rest : Return to Reservoir (1) (2) (3) (4)

. . . .

Raise solenoid valve Raise spool Flow Compensating Spool Load check valve

(5) . Lift Cylinder Safety Valve (6) . Lowering dosing valve (7) . Lowering solenoid valve

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Hydraulic systems - Three-point hitch control valve

Spool Valve EDC - Lowering (2)

WLAPL4S35C609G

: Pump pressure oil : Return to Reservoir (1) (2) (3) (4)

. . . .

Raise solenoid valve Raise spool Flow Compensating Spool Load check valve

(5) . Lift Cylinder Safety Valve (6) . Lowering dosing valve (7) . Lowering 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 the hydraulic lift control spool valve . . . . 4

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

84568014 22/03/2013 EN

SERVICE MANUAL Hitches, drawbars, and implement couplings

T5.105 T5.115 T5.95

84568014 22/03/2013

Contents Hitches, drawbars, and implement couplings - 37

[37.110] Rear three-point hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1 T5.105 , T5.115 , T5.95

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Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110

T5.105 T5.115 T5.95

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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 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Rear three-point hitch External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Rear hitch housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - General specification Implement hitching device data Type Category: Draft control Stabilizer devices Stabilizers Lower links Draft control

three-point linkage 2a 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 LIFTING 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 center of gravity at 610 mm (24.0157 in) from the ends of the arms, with maximum working pressure:

• with horizontal arms without supplementary cylinders

3161 kg (6969 lb)

• with two supplementary cylinders (on request)

4548 kg (10026 lb)

• for the entire lifting stroke without supplementary cylinders with two supplementary cylinders (on request)

2753 kg (6069 lb)

• 3467 kg (7643 lb) • with two supplementary cylinders (on request)

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Torque

WLAPL4S35C602G

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)

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)

Rear three-point hitch - Special tools 380000224 : Hydraulic lift lifting hook. 380000467 : Lift piston assembly strap (optional)

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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

291359-2 : Hydraulic lift lifting hook

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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.

free the bottom steps of the right-hand ladder with the retainer (1) , raise it, with the knob (2) , take off the battery cover, detach the battery electric cable.

Lock the front wheels with appropriate chocks.

Using a hoist and cable (1) raise the rear part of the tractor, positioning two fixed stands under the final drives, then remove the right-hand and left-hand wheels (2).

WLAPL4S10C101A

MOIL12APL0085AA

MOIL12APL0058AA

Detach the lock pin (1) and the support pin (2), then remove the top link (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 fitting (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 gearbox, making sure not to crush any piping or wiring during the procedure.

10.

MOIL12APL0086AA

MOIL12APL0039AA

MOIL12APL0059AA

MOIL12APL0060AA

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Hitches, drawbars, and implement couplings - Rear three-point hitch

11.

12.

Detach the control tie-rods (1) from the spool valve levers.

MOIL12APL0061AA

Using a suitable hoist, support the auxiliary spool valves unit, take out the retaining bolts (1) and extract the unit from the tractor. Set the unit on a workbench.

13.

If fitted, detach the gear-synchronized power takeâ&#x2C6;&#x2019;off 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.

Detach the top link support bracket (1). Take out the screws (2) fixing the lift casing to the transmissiongearbox casing.

MOIL12APL0088AA

MOIL12APL0089AA

MOIL12APL0090AA

Secure the tool 380000238 (1) to the lift.

18.

Connect the 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 casing, carefully clean and degrease the mating surfaces, then apply a bead of sealing compound of approximately 2 mm (0.0787 in) in diameter along the marked line shown in the drawing (see. Rear axle housing - Exploded view Sealing compound application diagram for transmission--gear box casing (27.100)).

Assemble the hydraulic lift using tools 380000238 and 380000224.

Secure the lift and potentiometer in position with the relative bolts.

Connect the power take−off control piping.

Connect the potentiometer connection, the relative tie-rod and the gear-synchronized power take−off lever.

Mount the auxiliary spool valve assembly on the lift casing.

Connect the flexible cables for spool valve control and adjust them according to (see. Remote control valve control lever - Adjust spool valve control flexible cables. (35.204)).

Connect the pipes to the diverter and to the trailer brake valve, where applicable.

Connect the auxiliary spool valves piping.

10.

Connect the power take−off speed sensor connection.

11.

Secure the top link strut support bracket.

12.

Remove the wooden strips and secure the rear cab support brackets to the reduction gear 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, install the cover and lower the right-hand steps.

18.

Check the transmission oil level and if necessary top up according to the quantities indicated (see. Consumables ()).

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Index Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110 Rear hitch housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rear hitch housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Rear three-point hitch - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear three-point hitch - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear three-point hitch - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 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

84568014 22/03/2013 EN

SERVICE MANUAL Steering

T5.105 T5.115 T5.95

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Contents Steering - 41

[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 T5.105 , T5.115 , T5.95

[41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 T5.105 , T5.115 , T5.95

[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 T5.105 , T5.115 , T5.95

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T5.105 T5.115 T5.95

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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 Hydraulic control components Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Power steering control valve Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power steering system Dynamic description Diagram showing 4WD power steering operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Power steering control valve Remove power steering spool valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install power steering spool valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Pressure test for the power steering relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

DIAGNOSTIC Hydraulic control components Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Hydraulic control components - Special tools Recommended tools 380000553: pressure gauge 0 - 250 bar (0.00 - 3625.00 psi) 380000621: Quick release coupling. 380000545: Hose. 380000570: T-fitting 380000599: Plug. 380000492: Quick coupler. 380000223: Steering wheel extractor. 380000240: Universal pressure control kit. 380000281: Tool for fitting ROTOGLYD seal on rotating valve.

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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

Hydraulic control components - Hydraulic schema Low pressure / power steering hydraulic circuit.

WLAPL4S21C305F

: Intake oil : Pump delivery oil : Oil at static rest : Oil at lubrication pressure (1) (2) (3) (4) (5) (6) (7) (8) (9)

Cooler. Steering pump. Power steering cylinders. Low pressure switch. Front differential lock. Power steering spool valve. Power take--off solenoid valve. Differential lock solenoid valve. Four-wheel drive line.

(10) PTO brake. (11) Electrohydraulic PTO unit. (12) Rear differential lock. (13) User spool valve. (14) Four wheel drive release solenoid valve. (15) Gearbox hydraulic spool valve. (16) Oil filter on delivery. (17) Oil filter on suction.

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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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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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- 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 - Remove power steering spool valve 1.

With the power steering spool valve connectors removed, note the position of the non return valve.

Support the power steering spool valve firmly in a vice using a pipe connector, as shown in

NOTE: the position of the feedthrough screw must remain the same in the phase of reassembly. 3.

Remove the screws of the terminal plate, the plate itself and the O-rings

WLAPL4S41C104A

WLAPL4S41C105A

WLAPL4S41C106A

WLAPL4S41C107A

Remove the dosing unit, the valve plate and the O-rings, observing the corresponding surfaces for correct reassembly

Extract the rotor drive shaft

Unscrew the check valve retainer and shake to make the check valve and suction valve come out

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Remove the relief valve assembly

NOTE: upon reassembly the relief valve must be calibrated to the correct pressure value. Follow the relevant procedural instructions provided in paragraph Power steering control valve - Pressure test for the power steering relief valve (41.200) .

WLAPL4S41C108A

WLAPL4S41C109A

WLAPL4S41C110A

WLAPL4S41C111A

Remove the internal and external couplings of the valve, the bearings and the thrust washer

NOTE: when removing the spool and the coupling make sure that the drive pin is in a horizontal position, so that it cannot fall into an internal gallery making it difficult to remove.

After removing the spool from the spool valve body, make sure you remove the oil seal.

ATTENTION: at the time of reassembly, check that the washer, part (1) is installed with the bevel facing towards the coupling of the valve. 10.

Remove the spool and the coupling from the spool valve,

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11.

Remove the centering springs

NOTE: the layout of the plates must remain the same at the time of reassembly. 12.

Remove the drive pin.

13.

Push inner sleeve out of outer sleeve.

14.

Remove the O-ring and thrust ring.

WLAPL4S41C112A

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Power steering control valve - Install power steering spool valve 1.

Assemble inner and outer sleeves so that the leaf spring slots align.

Install the control dowel rod

WLAPL4S41C112A

WLAPL4S41C113A

WLAPL4S41C111A

WLAPL4S41C114A

Install the late springs and push them fully in position.

Install the plate spring retainer and the bearing

NOTE: the inner ring of the bearing must be positioned with the beveled side facing towards the spool (see figure 3 ).

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Apply a light coating of hydraulic oil onto the sleeve and insert it into the body of the power steering spool valve.

Lubricate the O-ring and the thrust ring with hydraulic fluid and position them on the drift guide for seal rings. - Use the special tool no. 380000281 to install the rotate-glyd type oil seal.

Position the seal ring guide tool in the sleeve and push downwards with a twisting motion.

Remove the tools once the seal has seated.

WLAPL4S41C115A

WLAPL4S41C116A

WLAPL4S41C117A

WLAPL4S41C118A

With the seal installed in the body of the spool valve, refit the rotor.

NOTE: ensure that the control is in a horizontal position to facilitate its reassembly.

10.

Once the rotor is correctly seated, refit the check and suction valves.

11.

Screw the check valve down to just below the surface of the spool valve body.

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12.

Refit the O-ring and reposition the terminal plate.

WLAPL4S41C119A

Reassembling the dosing unit 1.

To aid reassembly install the rotor of the spool valve body so that the drive pin is perpendicular to the front face of the body.

Install the drive shaft into the body of the power steering spool valve, ensuring that the shaft engages correctly over the drive pin.

Fit the rotor and the stator of the dosing unit and install new slightly lubricated O-rings on each side of the stator,

Fit the dosing unit (rotor and stator) on the drive shaft.

WLAPL4S41C106A

WLAPL4S41C105A

WLAPL4S41C121A

Install the terminal plate and the relevant screws, ensure that the feedthrough screw (1) is inserted in position .7. Tighten the screws in two steps, first to half of the prescribed torque then, secondly, to the prescribed torque, respecting the sequence shown in the figure.

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Install the relief valve unit, parts (1) , (2) and (3) , leaving out the cap, part (4) , until the valve has been calibrated.

Check to ensure the power steering spool valve turns freely without meeting any resistance.

NOTE: The relief valve must be set to the correct pressure setting after the power steering spool valve has been re-assembled. Follow the relevant procedural instructions provided in Power steering control valve - Pressure test for the power steering relief valve (41.200) . 8.

After correctly calibrating the relief valve, reinstall the power steering spool valve on the mounting bracket and tighten the fixing screws to the prescribed torque

Reconnect the steering system hoses and tighten them to the prescribed torque

10.

Bleed the air from the system by turning the steering wheel from lock to lock until the system functions correctly.

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WLAPL4S41C120A

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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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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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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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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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. Steering wheel jolts, Incorrect synchronization of hydrostatic uncontrollable steering, steering. wheels turning in the opposite direction to that desired. Pipes to cylinder inverted. The wheels do not Hydraulic cylinder piston seal worn. 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)). Difficulty in steering in Insufficient pressure. Check the hydraulic pump and the pressure general, or only in one relief valve calibration ( (22), Hydraulic direction. control components - Exploded view (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 - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic control components - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic control components - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Power steering control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Power steering control valve - Install power steering spool valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Power steering control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Power steering control valve - Pressure test for the power steering relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Power steering control valve - Remove power steering spool valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Power steering control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Power steering control valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Power steering system - Dynamic description Diagram showing 4WD power steering operation . . . . . . . . . . . . . . 7

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Steering - 41 Pump - 206

T5.105 T5.115 T5.95

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Contents Steering - 41 Pump - 206

TECHNICAL DATA Power steering pump General specification power steering / low pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Power steering pump Pressure test power steering/low pressure circuit pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Steering - Pump

Power steering pump - General specification power steering / low pressure Type Location Pump Type Location Manufacturer Method of operation 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 nominal flow rate for new pump

Spool valve main data Spool valve: Type:

ORBITROL, with the rotating valve controlled directly by the steering column; the steering continues to function even if the pump is damaged

Manufacturer: DANFOSS OSPC 125 CR OGNIBENE STH ON 80 1st G170 LNV Abbreviation 2nd Abbreviation Pressure relief valve calibration ( (22) Hydraulic control 170 bar (2465.00 psi) components - Exploded view (41.200))

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Steering - Pump

Power steering pump - Pressure test power steering/low pressure circuit pump NOTE: There is no pressure relief valve in the power steering hydraulic pump. The following practical test will determine if the power steering pump delivery is sufficient to allow satisfactory operation of the power steering system.

WLAPL4S41C101A

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

Power steering test 1.

Set engine speed to 1100 RPM.

Quickly turn the steering wheel from lock to lock. If the power steering is operating correctly the reaction of the steering should be immediate with no time delay between turning the steering wheel and movement of the wheels.

At full lock the relief valve in the power steering spool valve should be heard to blow and the engine speed should drop to approximately 970 RPM. If the gearbox/power steering low pressure warning light comes on when the steering wheel is held at full lock position, this indicates that the hydraulic pump has an internal leak. Check the torque of the hydraulic pump mounting bolts and if tight, examine the hydraulic pump for leaking seals or wear.

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Steering - Pump

Steering Circuit Pressure Test 1.

Install the T-adapter 380000570 (1) and the quick release fitting 380000492 (3) in the hose for connecting to the steering cylinder.

Connect a pressure gauge with scale from 0 250 bar (0.00 - 3625.00 psi) (0 - 3600 lbf/in2) 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 full lock and hold it in this position.

The pressure reading must be 186 bar (2697.00 psi) (2700 lbf/in2) .

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WLAPL4S41C102A

Index Steering - 41 Pump - 206 Power steering pump - General specification power steering / low pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Power steering pump - Pressure test power steering/low pressure circuit pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Steering - 41 Cylinders - 216

T5.105 T5.115 T5.95

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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

84568014 22/03/2013 EN

SERVICE MANUAL Wheels

T5.105 T5.115 T5.95

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Contents Wheels - 44

[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 T5.105 , T5.115 , T5.95

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Wheels - 44 Front wheels - 511

T5.105 T5.115 T5.95

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Contents Wheels - 44 Front wheels - 511

SERVICE Front wheels Check 4 WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Wheels - Front wheels

Front wheels - Check 4 WD Checking 4 WD front wheel alignment of four-wheel drive tractors must be parallel to the longitudinal axis of the tractor, alternatively a slight tolerance of ± 3 mm (0.118 in) is permissible. (A) = (B) ± 3 mm (0.118 in) To check the exact value of the toe-in setting of four-wheel drive tractors, proceed as follows: 1.

Inflate the front tires to the prescribed pressure.

Place the steering wheel at mid-travel, with one spoke along the tractor centre line.

Check if wheels are parallel to the tractor centre line.

On the horizontal plane passing between the centres of the wheels, measure the distance (A) between the front inside edges of the rims.

Turn both front wheels through 180 ° (180.00 °) then, at the height of the wheel hub centres, measure the distance (B) between the rear inside edges of the wheel rims, checking that the new measurement is equal to or greater than distance (A) by a maximum of 3 mm (0.118 in). The rotation of the wheels through 180 ° (180.00 °) is required in order to eliminate the effect on the measurement of any wear on the rims.

If wheel toe-in needs to be adjusted, remove nut (2) and extract the track rod end (1) from its housing.

Loosen lock nut (3) and screw the track rod end (1) in or out to decrease or increase the distance ( (2), 1).

Reposition the track rod end (1) in the housing and check the toe-in as described in points 4 and 5.

After having adjusted the toe-in to within the prescribed limits, tighten lock nut (3) to a torque value of 180 N·m (1593.13 lb in) and nut (2) to 100 N·m (885.07 lb in).

NOTE: Self-locking nut (2) must be replaced each time it is removed or unscrewed.

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SEZ44CAP1A-24OK

SEZ44CAP1A-25

Index Wheels - 44 Front wheels - 511 Front wheels - Check 4 WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

84568014 22/03/2013 EN

SERVICE MANUAL Electrical systems

T5.105 T5.115 T5.95

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Contents Electrical systems - 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 T5.105 , T5.115 , T5.95

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 T5.105 , T5.115 , T5.95

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 T5.105 , T5.115 , T5.95

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 T5.105 , T5.115 , T5.95

[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 T5.105 , T5.115 , T5.95

[55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 T5.105 , T5.115 , T5.95

[55.024] Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 T5.105 , T5.115 , T5.95

[55.523] Cab hitch controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 T5.105 , T5.115 , T5.95

[55.130] Rear three-point hitch electronic control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 T5.105 , T5.115 , T5.95

[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 T5.105 , T5.115 , T5.95

[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 T5.105 , T5.115 , T5.95

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Electrical systems - 55 Electrical system - 000

T5.105 T5.115 T5.95

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Contents Electrical systems - 55 Electrical system - 000

TECHNICAL DATA Electrical system Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Electrical system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Static description Circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Electrical system Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Electrical systems - Electrical system

Electrical system - Torque TORQUE WRENCH 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 system - Dynamic description STARTING SYSTEM (DESCRIPTION AND OPERATION) All systems consist of an ignition key-switch, heavy-duty wiring, a starter motor with an electromagnet, a starter relay and clutch pedal switch. These are the circuit components used on these machines. There are two types of gearbox: one with an electro-hydraulic shuttle (12X12), with the addition of the creeper unit (20X20), one with an electro-hydraulic shuttle and with Hi Lo functions (24X24). Only one starter motor available with power rating 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. When the contact of the start switch is closed, with the clutch pedal pressed and the shuttle lever in neutral the coils of the electromagnet are excited and the mobile core is magnetically attracted inside the electromagnet. 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 pull-in coil is connected to the positive battery pole through the starter switch, while the other end in connected to the positive 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 connect completely as soon as the starter motor starts turning. 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 re-opens 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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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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Electrical system - Electrical test STARTING SYSTEM TEST ON TRACTOR To troubleshoot the starting system simply and rapidly with conclusive results, use a battery/starter tester (high discharge rate tester) with incorporated 0 - 20 V voltmeter and 0 - 500 A ammeter. When using testing devices, follow test procedures recommended by the manufacturer. If testing devices are not available, carry out the following procedure using a standard 0 - 20 V voltmeter and a 0 - 500 A ammeter to check correct starter motor operation, without removing it from the engine. Before the test: • Check that the battery is fully charged • Check the condition of all the starting system wiring (no damaged or frayed wires, no loose connections). • Check that the engine is not seized.

CURRENT ABSORBED ON THE STARTER MOTOR CIRCUIT 1.

Disconnect the battery (3) ground cable (negative).

Disconnect the positive battery cable from the starter electromagnet (5). Connect the positive lead of an ammeter (1) to the positive battery terminal and the negative lead to the electromagnet input terminal (5).

Reconnect the ground wire (negative) to the battery negative terminal (3).

Connect the positive voltmeter point (2) to the positive battery terminal clamp and the negative to the negative battery terminal clamp.

Disconnect the injection pump closing solenoid valve wire.

Run the engine and note voltmeter and ammeter readings. Voltage must remain constantly around 12 V with an absorption value of 250 300 A.

•

If the absorption value corresponds with the technical data, the starter motor (4) is working correctly. If voltage drops during the test, carry out the “Starting system circuit resistance” test (see the relative heading).

•

If the absorption value exceeds that of the technical data, check the circuit as described below. If the starting system circuit tests are satisfactory, then the starter motor is faulty and will need to be removed in order to identify the cause.

•

If the current absorption value is lower than that of the technical data, then the starter motor is faulty and will need to be removed in order to identify the cause.

SEZ55CAP3A-4

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STARTING SYSTEM CIRCUIT RESISTANCE (VOLTAGE DROP) If the voltage absorption value is too high, check the individual circuit components to find the cause of the voltage drop. ATTENTION: Disconnect the fuel injection pump shut-off solenoid valve wire.

SEZ55CAP3A-5

SEZ55CAP3A-3

SEZ55CAP3A-6

Battery positive cable 1.

Connect the positive voltmeter point (1) to the positive battery terminal clamp (2).

Connect the negative lead on the voltmeter to the starter motor electromagnet terminal (3).

Run the engine and check the voltmeter readings. If voltage exceeds 0.2 V, check and tighten the cable connections. Re-check the voltage and, if the value is still too high, replace the cable.

Starter motor ground connections 1.

Connect the positive lead on the voltmeter (1) to the starter motor casing (2).

Connect the negative lead on the voltmeter to the engine block (3).

Run the engine and check the voltmeter readings. If the value exceeds 0.2 V, check the ground connections between the starter motor flange and the engine rear cover.

Battery ground lead 1.

Connect the positive lead on the voltmeter (1) to the engine block (2).

Connect the negative lead on the voltmeter to the negative terminal on the battery (3).

Run the engine and check the voltmeter readings. If voltage exceeds 0.2 V, check and tighten the ground cable connections. Re-check the voltage and, if the value is still too high, replace the ground cable.

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Index Electrical systems - 55 Electrical system - 000 Electrical system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical system - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electrical system - Static description Circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical system - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Harnesses and connectors - 100

T5.105 T5.115 T5.95

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Wire harnesses Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Overview HOW TO USE THE WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Identification ELECTRICAL SYSTEMS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Identification ELECTRICAL SYSTEMS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 T5.95 NA, T5.105 NA, T5.115 NA

Electrical schematic frame 01 BATTERY, ALTERNATOR AND POWER SUPPLY UNIT (with and without battery isolator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Electrical schematic frame 02 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Electrical schematic frame 03 ELECTRONIC LIFT (EDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Electrical schematic frame 04 POWER TAKE-OFF, 4-WHEEL DRIVE AND DIFFERENTIAL LOCK . . 46 Electrical schematic frame 05 AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Electrical schematic frame 06 WORK LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Electrical schematic frame 06 WORK LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 T5.95 NA, T5.105 NA, T5.115 NA

Electrical schematic frame 07 LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Electrical schematic frame 07 LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 T5.95 NA, T5.105 NA, T5.115 NA

Electrical schematic frame 08 WINDSCREEN WIPER AND ROTATING BEACONS . . . . . . . . . . . . . . . . 60 Electrical schematic frame 09 AUXILIARY SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Electrical schematic frame 10 BRAKE LIGHTS, LICENSE PLATE LIGHT AND THIRD SPOOL VALVE 68 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Electrical schematic frame 10 BRAKE LIGHTS, LICENSE PLATE LIGHT AND THIRD SPOOL VALVE 72 T5.95 NA, T5.105 NA, T5.115 NA

Electrical schematic frame 11 CAN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Electrical schematic frame 13 TRANSMISSION CONTROL (first part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Electrical schematic frame 14 TRANSMISSION CONTROL (second part) . . . . . . . . . . . . . . . . . . . . . . . . 78 Electrical schematic frame 15 CONTROL PANEL (First part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Electrical schematic frame 16 CONTROL PANEL (Second part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Electrical schematic frame 16 CONTROL PANEL (Second part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 T5.95 NA, T5.105 NA, T5.115 NA

Electrical schematic frame 17 ENGINE (First part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Electrical schematic frame 18 ENGINE (Second part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

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Electrical schematic frame 19 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Electrical schematic frame 19 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 T5.95 NA, T5.105 NA, T5.115 NA

Electrical schematic frame 20 ROOF RELAYS AND FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Electrical schematic frame 21 LIGHTS AND FLASHERS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Electrical schematic frame 21 LIGHTS AND FLASHERS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 T5.95 NA, T5.105 NA, T5.115 NA

Electrical schematic frame 22 FRONT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Electrical schematic frame 23 ITALIAN MARKET TRAILER BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . 102 Electrical schema TRANSMISSION CONTROL UNIT, ELECTRONIC LIFT, 4 DRIVING WHEELS, DIFFERENTIAL LOCK, POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Electrical schema ADIC CONTROL PANEL CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Wire connectors Component Diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Component diagram 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Component diagram 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Component diagram 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Component diagram 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Component diagram 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Component diagram 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Component diagram 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Component diagram 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Component diagram 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Component diagram 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Component diagram 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Component diagram 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Component diagram 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Component diagram 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 Component diagram 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Component diagram 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 Component diagram 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Component diagram 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 Component diagram 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 Component diagram 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Component diagram 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 Component diagram 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Component diagram 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 Component diagram 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Component diagram 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Component diagram 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Component diagram 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Component diagram 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 84568014 22/03/2013

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Component diagram 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Component diagram 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Component diagram 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 Component diagram 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Component diagram 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 Component diagram 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 Component diagram 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Component diagram 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 Component diagram 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 Component diagram 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 Component diagram 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 Component diagram 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 Component diagram 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 Component diagram 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Component diagram 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 Component diagram 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 Component diagram 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 Component diagram 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 Component diagram 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 Component diagram 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 Component diagram 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 Component diagram 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 Component diagram 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377 Component diagram 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 Component diagram 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391 Component diagram 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

Fuse and relay box Component localisation MAXI power fuses box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397 Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399 Static description Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

SERVICE Wire harnesses Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 Rewire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 Measure Digital multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417

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Electrical systems - Harnesses and connectors

Wire harnesses - Component localisation INDEX TO WIRING HARNESS TABLES Table 1 2 3 4 5 6 7 8 9

Designation Engine cable left side ( 1) Engine cable right side ( 2) Engine outfit cable left side ( 3) Engine outfit cable right side ( 4) Transmission cable ( 5) Main cable left side ( 6) Main cable right side ( 7) Cab roof cable ( 8) Headlights extension cable ( 9)

DESIGNATION ALTERNATOR Alternator BATTERY Battery NODE BLOCK Jumper wire (Shunt) CONNECTOR Alarm buzzer connector BDS set diode connector Kam 2 extension connector Roof lights connector Lights jumper wire connector Lights jumper wire connector Front loader prearrangement connector Rotating beacon right-hand socket extension Rotating beacon left-hand socket extension 3rd spool valve splitter solenoid extension Cab - front loader splitting Transmission cab splitting Engine cables 1 and 2 splitting (6-way connector) Splitting cable for FTP - engine 2 Splitting cable for FTP - engine 2 (injectors) Cab roof main cable splitting Cab roof cable 2 splitting Italian license plate light extension splitting Extension splitting Kam 2 License plate light splitting Trailer brake splitting Starter motor ground splitting Engine - cab splitting PDU splitting Cab power splitting Cab transmission power splitting Headlights splitting Right fan splitting Left fan splitting Front loader prearrangement jumper wire ISO/NASO socket extension DIODE BDS diode set Front loader jumper wire diode 84568014 22/03/2013

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CODE G-001 G-002 W-001 X-389 X-551 X-552 X-063 X-035B X-035C X-392 X-071 X-073 X-087 X-380 X-300 X-949 X-941 X-940 X-050 X-385 X-095A X-553 X-095 X-381 X-570 X-001 X-002 X-160 X-370 X-025 X-047 X-046 X-392A X-098 V-001 V-002

Electrical systems - Harnesses and connectors

DESIGNATION AUDIO DEVICES RH speaker LH speaker Horn Alarm buzzer Radio VAR PTO switch on the left fender Front loader antidamping switch HVAC switch Ignition switch Low gearbox oil pressure switch Differential lock switch Front loader implement locking switch Lights switch Emergency switch Rotating beacon switch Air filter clogged switch Handbrake Switch Home - enter switch 4 WD engagement switch Brake oil level switch Lights switch Work lights switch PTO engagement modulation switch Right brake pedal switch Left brake pedal switch Clutch pedal switch Brake pedals not connected switch Door switch Operator present switch Air conditioning pressure switch on the filter Engine oil pressure switch Rear PTO Switch PTO switch on the right fender Reactivity switch R2 gear range sensing switch R1 gear range sensing switch G gear sensing switch Synchronized power take-off sensing switch Creeper unit sensing switch 3rd spool valve splitter switch Trailer brake safety switch Lift switch on the right fender Lift switch on the left fender Differential lock warning light switch Handbrake indicator light switch Battery cut-out switch Up - down switch Front wiper and full-beam/low-beam headlight switch Rear window wiper switch Fan speed switch Front loader joystick switches Shuttle lever Clutch pressure switch A 84568014 22/03/2013

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CODE H-003 H-004 H-001 H-005 H-002 S-011 S-061 S-024 S-038 S-014 S-055 S-060 S-026 S-033 S-029 S-018 S-019 S-053 S-056 S-022 S-030 S-028 S-012 S-035 S-034 S-002 S-017 S-027 S-016 S-025 S-005 S-008 S-010 S-051 S-048 S-049 S-046 S-013 S-021 S-036 S-037 S-004 S-003 S-007 S-020 S-015 S-054 S-032 S-031 S-023 S-044 S-001 S-058

Electrical systems - Harnesses and connectors

DESIGNATION Clutch pressure switch B LAMPS AND LEDS Soft start switch backlighting connector PTO Front RH light Front LH light Right rear flasher light Rear left flasher light RH tail light LH tail light Air conditioning panel illumination Spot lamp Right swivel lamp Left swivel lamp Right license plate light on the roof Front right work light Front left work light Worklamp Rear Right Hand Worklamp Rear Left Hand Work light on front right handrail Work light on front left handrail Left license plate light on the roof Console Light Right-hand light Left-hand light Cigarette lighter backlighting Optional cigar lighter backlighting Differential lock switch backlighting Lights switch backlighting Rotating beacon switch backlighting Home - enter switch backlighting 4 WD engagement switch backlighting Lights switch backlighting Reactivity switch backlighting Up - down switch backlighting Battery disconnect switch backlighting Rear window wiper switch backlighting MASS Ground 1 of the gearbox control unit Alternator ground Engine ground Starter motor ground Ground for 40 A socket Panel ground Fuse and relay box n 2 ground Cab roof ground n 2 Ground via chassis CONTROL UNIT MODULE Air-conditioning control unit Dashboard control unit Engine ECU Glow plug module connector Cab fuse and relay module connector Transmission control unit ( XCM ) Battery isolator control module ( BDS ) Electronic lift LED module

CODE S-059 E-027 E-017 E-016 E-019A E-018A E-019 E-018 E-003 E-005 E-013 E-012 E-026 E-008 E-009 E-006 E-007 E-010 E-011 E-025 E-004 E-015 E-014 E-028 E-029 E-034 E-037 E-020 E-032 E-035 E-021 E-036 E-033 E-002 E-022 GND-006 GND-001 GND-009 GND-002 GND-011 GND-008 GND-005 GND-010 GND-000 A-012 A-009 A-010 A-011 A-013 A-001 A-007 A-016

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Electrical systems - Harnesses and connectors

DESIGNATION Clutch engagement button module Front windscreen wiper timer module Electronic lift mouse ( EDC ) Fuses and relays panel Engine supply box ( PDU ) Flasher unit ENGINE Air-conditioning actuator Starter motor EGR motor Front wiper spray pump Rear wiper spray pump Pneumatic seat Front windscreen wiper for openable window Front windscreen wiper for closed window Rear window wiper TVA valve Right fan Left fan RESISTANCE Cylinder 1 glow plug Cylinder 2 glow plug Cylinder 3 glow plug Cylinder 4 glow plug Fuel heater Right fan resistor Left fan resistor TRANSMITTER SENSOR Exhaust gas temperature sensor connector on the manifold Lift potentiometer panel Electronic lift right draft pin Electronic lift left draft pin Air conditioning temperature potentiometer Radar Water in fuel sensor Pre- and post-pressure difference sensor DPF Fuel level sensor Accelerator pedal sensor Accelerator pedal sensor Clutch pedal sensor Arms position sensor Fuel temperature sensor Air temperature sensor Pre-catalyst exhaust gas temperature sensor Particulate pre-filter exhaust gas temperature sensor ( DPF ) Coolant temperature sensor Transmission temperature sensor Speed sensor Crankshaft Speed Sensor Speed sensor PTO Fuel volume sensor Lambda probe Frost thermostat SOLENOID Air conditioning compressor

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CODE A-002 A-020 A-004 A-006 A-008 A-014 M-004 M-001 M-011 M-008 M-009 M-010 M-007 M-006 M-005 M-012 M-003 M-002 R-002 R-003 R-004 R-005 R-001 R-007 R-006 B-009 B-017 B-020 B-019 B-031 B-021 B-029 B-028 B-023 B-013 B-015 B-014 B-018 B-006 B-024 B-027 B-026 B-007 B-011 B-005 B-010 B-022 B-008 B-025 B-030 Y-013

Electrical systems - Harnesses and connectors

DESIGNATION

CODE Y-006 Y-005 Y-017 Y-010 Y-016 Y-011 Y-015 Y-008 Y-007 Y-014 Y-018 Y-001 Y-002 Y-003 Y-004 Y-009 Y-012

EDC lowering solenoid valve EDC lifting solenoid valve Wastegate solenoid valve Injector, Cylinder No. 1 Injector, Cylinder No. 2 Injector, Cylinder No. 3 Injector, Cylinder No. 4 Differential lock solenoid 4 WD disengagement solenoid Trailer brake solenoid Trailer brake solenoid Clutch A solenoid Clutch B solenoid Clutch C solenoid Clutch D solenoid Rear PTO solenoid 3rd spool valve splitter solenoid PLUG 8 A socket 25 A socket 40 A socket Cigar Lighter Socket Optional cigar lighter socket Front loader socket Rotating beacon right-hand socket Diagnostic socket ISO 11786 socket ISO/NASO socket Rotating beacon left-hand socket

J-001 J-004 J-005 J-002 J-003 J-011 J-006 J-009 J-010 J-008 J-007

LINK BETWEEN DIAGRAM TABLES AND WIRING HARNESS TABLES Component

A-001

A-002 A-004

Wiring diagram table

Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100)

Description

Wiring harness diagram table

Connector

Transmission control unit ( XCM ) X-200 , X-210 , 6 X-220 , X-230 , X-240

Clutch engagement button module Electronic lift mouse ( EDC )

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X-320

X-326

Electrical systems - Harnesses and connectors

Component

A-006

A-007 A-008

A-009

A-010

A-011 A-012 A-013 A-014 A-016 A-020 B-001 B-002 B-003

Wiring diagram table

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 13 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 22 (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 15 (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 18 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 20 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100)

Description

Fuses and relays panel

Wiring harness diagram table

Connector

X-110 , X-120 , 7 X-130 , X-140

Battery isolator control module ( X-008 , X-009 4 BDS ) X-003 , X-004 , 4 Engine supply box ( PDU ) X-005 , X-006 , X-007 , X-014 , X-049 , X-533 Dashboard control unit X-377 , X-450 , 7 X-460

Engine ECU

X-937 , X-939

Glow plug module connector

X-938

Air-conditioning control unit

X-045

Cab fuse and relay module connector Flasher unit

X-150

X-090

Electronic lift LED module

X-534

Front windscreen wiper timer X-048 module Air pressure/temperature sensor X-961

Phase sensor

X-962

1-2

Exhaust gas pressure sensor on X-963 the manifold

1-2

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Electrical systems - Harnesses and connectors

Component

B-004 B-005 B-006 B-007 B-008 B-009 B-010 B-011 B-013 B-014 B-015 B-017 B-018 B-019 B-020 B-021 B-022 B-023 B-024 B-025 B-026 B-027 B-028 B-029 B-030 B-031 E-002

Wiring diagram table

Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 03 (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 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 17 (55.100) Wire harnesses - Electrical schematic frame 17 (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)

Description

Wiring harness diagram table

Connector

Rail pressure sensor

X-967

Speed sensor

X-309

Fuel temperature sensor

X-968

1-2

Coolant temperature sensor

X-969

1-2

Fuel volume sensor

X-970

1-2

Exhaust gas temperature sensor X-971 connector on the manifold X-965 Crankshaft Speed Sensor

1-2

Transmission temperature sensor Accelerator pedal sensor

X-316

X-321

Clutch pedal sensor

X-322

Accelerator pedal sensor

X-324

Lift potentiometer panel

X-327

Arms position sensor

X-328

Electronic lift left draft pin

X-331

Electronic lift right draft pin

X-332

Radar

X-333

Speed sensor PTO

X-341

Fuel level sensor

X-354

Air temperature sensor

X-942

Probe lamda

X-943

Particulate pre-filter exhaust gas temperature sensor ( DPF ) Pre-catalyst exhaust gas temperature sensor Pre- and post-pressure difference sensor DPF Water in fuel sensor

X-945

X-946

X-947

X-950

Frost thermostat

X-044

Air conditioning temperature potentiometer Battery isolator switch backlighting

X-041

X-198

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Electrical systems - Harnesses and connectors

Component

E-003 E-004 E-005 E-006 E-007 E-008 E-009 E-010 E-011 E-012 E-013 E-014 E-015 E-016 E-017 E-018 E-018A E-019 E-019A E-020 E-021 E-022 E-025 E-026 E-027 E-028 E-029

Wiring diagram table

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 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) 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 08 (55.100) Wire harnesses - Electrical schematic frame 21 (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 04 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100)

Description

Wiring harness diagram table

Connector

Air conditioning panel illumination X-040

Spot lamp

X-051 , X-052 , 8 X-053 X-054 8

Worklamp Rear Right Hand

X-055

Worklamp Rear Left Hand

X-056

Front right work light

X-057

Front left work light

X-058

Work light on front right handrail X-059

Work light on front left handrail

X-060

Left swivel lamp

X-017

Right swivel lamp

X-018

Left-hand light

X-019

Right-hand light

X-020

Front LH light

X-021

Front RH light

X-022

LH tail light

X-023

Rear left flasher light

X-386

RH tail light

X-024

Right rear flasher light

X-387

Rotating beacon switch backlighting Lights switch backlighting

X-033

X-035

Rear window wiper switch X-037 backlighting Left license plate light on the roof X-096

Right license plate light on the roof Soft start switch backlighting connector PTO Cigarette lighter backlighting

X-097

X-388

X-080

Optional cigar lighter backlighting X-081

Console Light

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Electrical systems - Harnesses and connectors

Component

E-032 E-033 E-034 E-035 E-036 E-037 G-001 G-002 GND-000

GND-001 GND-002 GND-005

GND-006 GND-008

Wiring diagram table

Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 15 (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 06 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 18 (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 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 14 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) 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 15 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100)

Description

Wiring harness diagram table

Connector

Switch backlighting home - enter X-270

Up - down switch backlighting

X-290

Differential lock switch backlighting 4 WD engagement switch backlighting Reactivity switch backlighting

X-303

X-314

X-369

Lights switch backlighting

X-062

Alternator

X-012 , X-013

Battery

X-500 , X-600

Ground via chassis

Alternator ground

Starter motor ground

Fuse and relay box n 2 ground

X-400

Ground 1 of the gearbox control X-280 unit Panel ground X-410

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Electrical systems - Harnesses and connectors

Component

Wiring diagram table

GND-009

Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 01 (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 20 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 14 (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) 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 11 (55.100)

GND-010

GND-011

H-001 H-002 H-003 H-004 H-005 J-001 J-002 J-003 J-004 J-005 J-006 J-007 J-008 J-009

Description

Wiring harness diagram table

Connector

Engine ground

X-420

Cab roof ground n 2

X-403

Ground for 40 A socket

X-401

Horn

X-015 , X-016

Radio

X-039

RH speaker

X-082 , X-083

LH speaker

X-084 , X-085

Alarm buzzer

X-389

8 A socket

X-026

Cigar Lighter Socket

X-027

Optional cigar lighter socket

X-028

25 A socket

X-078 , X-079

40 A socket

X-402 , X-501

Rotating beacon right-hand socket Rotating beacon left-hand socket -

ISO socket

X-099

Diagnostic socket

X-376

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Electrical systems - Harnesses and connectors

Component

J-010 J-011 M-001 M-002 M-003 M-004 M-005 M-006 M-007 M-008 M-009 M-010 M-011 M-012 R-001 R-002 R-003 R-004 R-005 R-006 R-007 S-001 S-002 S-003 S-004 S-005 S-007

Wiring diagram table

Wire harnesses - Electrical schematic frame 16 (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 05 (55.100) 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 08 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 14 (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 16 (55.100)

Description

Wiring harness diagram table

Connector

ISO 11786 socket

X-378

Front loader socket

X-395

Starter motor Left fan

X-010 , X-011 , 4 X-304 7 X-046A

Right fan

X-047A

Air-conditioning actuator

X-043

Rear window wiper

X-038

Front windscreen wiper for closed window Front windscreen wiper for openable window Front wiper spray pump

X-074

X-075

X-076

Rear wiper spray pump

X-077

Pneumatic seat

X-029

EGR motor

X-964

1-2

TVA valve

X966

Fuel heater

X-362

Cylinder 1 glow plug

X-955

Cylinder 2 glow plug

X-956

Cylinder 3 glow plug

X-957

Cylinder 4 glow plug

X-958

Left fan resistor

X-973

Right fan resistor

X-972

shuttle lever

X-318

Clutch pedal switch

X-319

Lift switch on the left fender

X-329

Lift switch on the right fender

X-330

Engine oil pressure switch

X-959

Differential lock warning light switch

X-340

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Electrical systems - Harnesses and connectors

Component

S-008 S-010 S-011 S-012 S-013 S-014 S-015 S-016 S-017 S-018 S-019 S-020 S-021 S-022 S-023 S-024 S-025 S-026 S-027 S-028

S-029 S-030 S-031 S-032

S-033 S-034

Wiring diagram table

Description

Wiring harness diagram table

Connector

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 01 (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 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 13 (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 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)

Rear PTO Switch

X-350

PTO switch on the right fender

X-349

PTO switch on the left fender

X-347

Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100)

X-351 PTO engagement modulation switch X-352 Synchronized power take-off sensing switch Low gearbox oil pressure switch X-371 , X-353

Battery cut-out switch

X-197

Operator present switch

X-355

Brake pedals not connected switch Air filter clogged switch

X-356

X-357

Handbrake Switch

X-358

Handbrake indicator light switch X-359 , X-399

6 5

Creeper unit sensing switch

X-368

Brake oil level switch

X-360

Fan speed switch

X-030

HVAC switch

X-031

Air conditioning pressure switch on the filter Lights switch

X-042

X-061

Door switch

X-064

Work lights switch

Rotating beacon switch

X-065 , X-066 , 8 X-067 , X-068 , X-069 X-032 8

Lights switch

X-034

Rear window wiper switch

X-036

Front wiper and full-beam/low-beam headlight switch

X-091

Emergency switch

X-092

Left brake pedal switch

X-093

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Electrical systems - Harnesses and connectors

Component

S-035 S-036 S-037 S-038 S-044 S-046 S-048 S-049 S-051 S-053 S-054 S-055 S-056 S-058 S-059 S-060 S-061 V-001 V-002 W-001 X-001

X-002 X-025

Wiring diagram table

Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 13 (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 04 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 22 (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) 7-11 Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100)

Description

Wiring harness diagram table

Connector

Right brake pedal switch

X-094

3rd spool valve splitter switch

X-086

Trailer brake safety switch

X-502 , X-503

Ignition switch Front loader joystick switches

X-509 , X-510 , 7 X-511 , X-512 X-317 , X-323 6

G gear sensing switch

X-301

R2 gear range sensing switch

X-199

R1 gear range sensing switch

X-308

Reactivity switch

X-313

Home - enter switch

X-250

Up - down switch

X-260

Differential lock switch

X-375

4 WD engagement switch

X-374

Clutch pressure switch A

X-100 , X-383

Clutch pressure switch B

X-504 , X-522

Front loader implement locking X-393 switch Front loader antidamping switch X-394

BDS diode set

X-551

Front loader jumper wire diode

X-295

Jumper wire ( Shunt )

Engine - cab splitting

X-001

3-7

PDU splitting

X-002

Headlights splitting

X-025

3-9

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Electrical systems - Harnesses and connectors

Component

X-035B X-035C X-046 X-047 X-050

X-063 X-071 X-073 X-087 X-095 X-095A X-098 X-160 X-300

X-370 X-380 X-381

Wiring diagram table

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 06 (55.100) Wire harnesses - Electrical schematic frame 08 (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 09 (55.100) 20 Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 02 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100)

Description

Wiring harness diagram table

Connector

Lights jumper wire connector

X-035B

Lights jumper wire connector

X-035C

Left fan splitting

X-046

6-7

Right fan splitting

X-047

Cab roof main cable splitting

X-050

7-8

Roof lights connector

X-063

Rotating beacon right-hand socket extension Rotating beacon left-hand socket extension 3rd spool valve splitter solenoid extension License plate light splitting

X-071

X-073

X-087

5-7

X-095

Italian license plate light extension splitting ISO/NASO socket extension splitting Cab power splitting Transmission cab splitting

X-095A

X-098

X-160 X-300

7-8 5-7

Cab transmission power splitting X-370

3-7

Cab - front loader splitting

X-380

Trailer brake splitting

X-381

5-7

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Electrical systems - Harnesses and connectors

Component

X-385

X-389 X-392 X-392A X-551 X-552 X-553 X-570 X-940 X-941 X-949 Y-001 Y-002 Y-003 Y-004 Y-005 Y-006 Y-007 Y-008 Y-009 Y-010 Y-011 Y-012

Wiring diagram table

Wire harnesses - Electrical schematic frame 01 (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 21 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 22 (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 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 13 (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 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100)

Description

Cab roof cable 2 splitting

X-385

Wiring harness diagram table 7-8

Alarm buzzer connector

X-389

Front loader prearrangement connector Front loader prearrangement jumper wire BDS set diode connector

X-392

X-392A

X-551

Kam 2 extension connector

X-552

Kam 2 extension splitting

X-553

Starter motor ground splitting.

X-570

Splitting cable for FTP - engine X-940 2 (injectors) Splitting cable for FTP - engine 2 X-941

Engine cables 1 and 2 splitting (6-way connector) Clutch A solenoid

X-949

X-364

Clutch B solenoid

X-365

Clutch C solenoid

X-806

Clutch D solenoid

X-807

EDC lifting solenoid valve

X-334

EDC lowering solenoid valve

X-335

4 WD disengagement solenoid

X-342

Differential lock solenoid

X-343

Rear PTO solenoid

X-344

Injector, Cylinder No. 1

X-951

Injector, Cylinder No. 3

X-952

1-2

3rd spool valve splitter solenoid

X-089

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Connector

Electrical systems - Harnesses and connectors

Component

Y-013 Y-014 Y-015 Y-016 Y-017 Y-018

Wiring diagram table

Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100)

Description

Wiring harness diagram table

Connector

Air conditioning compressor

X-088

Trailer brake solenoid

X-363

Injector, Cylinder No. 4

X-953

1-2

Injector, Cylinder No. 2

X-954

1-2

Wastegate solenoid valve

X-960

1-2

Trailer brake solenoid

X-384

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Electrical systems - Harnesses and connectors

WLAPL4S55C701H

engine cable left side

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Electrical systems - Harnesses and connectors

WLAPL4S55C702H

engine cable right side

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Electrical systems - Harnesses and connectors

NOTE: engine outfit cable left side: The letters, in a square frame, show where the wiring harness has been disconnected. To see the continuation, refer to the following table.

WLAPL4S55C703H-

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Electrical systems - Harnesses and connectors

NOTE: engine outfit cable right side: The letters, in a square frame, show where the wiring harness has been disconnected. To see the continuation, refer to the previous table.

WLAPL4S55C704H-

engine cable right side 84568014 22/03/2013

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Electrical systems - Harnesses and connectors

WLAPL4S55C705H

transmission cable

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Electrical systems - Harnesses and connectors

NOTE: The letters, in a square frame, show where the wiring harness has been disconnected. To see the continuation, refer to the following table.

WLAPL4S55C706H

main cable left side 84568014 22/03/2013

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Electrical systems - Harnesses and connectors

NOTE: The letters, in a square frame, show where the wiring harness has been disconnected. To see the continuation, refer to the previous table.

WLAPL4S55C707H

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Electrical systems - Harnesses and connectors

WLAPL4S55C708H

cab roof cable

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Electrical systems - Harnesses and connectors

WLAPL4S55C709H

Headlights extension cable

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

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 (e.g. F indicates a fuse, C indicates a connector, MOD indicates a module, SW indicates a connector, etc.), - the numerical portion is a progressive number.

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Electrical systems - Harnesses and connectors

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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Electrical systems - Harnesses and connectors

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

WIRE COLOUR CODING B N LN S R O Y

Black Brown Light Brown Slate Red Orange Yellow

G LG U TQ L K W

Green Light Green Blue Turquoise Lilac Pink White

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 Pin 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 J-001 Q-001 Z-001

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Electrical systems - Harnesses and connectors

Wire harnesses - Identification ELECTRICAL SYSTEMS INDEX T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Wiring diagrams for ISO markets Table 01/23 01/23 02/23 03/23 04/23 05/23 06/23 07/23 08/23 09/23 10/23 11/23 13/23 14/23 15/23 16/23 17/23 18/23 19/23 20/23 21/23 22/23 23/23

Topic covered BATTERY, ALTERNATOR AND POWER SUPPLY UNIT BATTERY, ALTERNATOR AND POWER SUPPLY UNIT FUSES ELECTRONIC LIFT ( EDC ) POWER TAKE-OFF, 4-WHEEL DRIVE AND DIFFERENTIAL LOCK AIR CONDITIONING WORK LAMPS LIGHTS WINDSCREEN WIPER AND ROTATING BEACONS AUXILIARY SOCKETS BRAKE LIGHTS, LICENSE PLATE LIGHT AND THIRD SPOOL VALVE CAN LINE TRANSMISSION CONTROL TRANSMISSION CONTROL CONTROL PANEL CONTROL PANEL ENGINE ENGINE RELAY ROOF RELAYS AND FUSES LIGHTS AND FLASHERS CONTROL FRONT LOADER ITALIAN TRAILER BRAKE VALVE

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Notes With battery isolator Without battery isolator

First part Second part First part Second part First part Second part

Electrical systems - Harnesses and connectors

Wire harnesses - Identification ELECTRICAL SYSTEMS INDEX T5.95 NA, T5.105 NA, T5.115 NA

Wiring diagrams for NASO markets Table 01/23 01/23 02/23 03/23 04/23 05/23 06/23 07/23 08/23 09/23 10/23 11/23 13/23 14/23 15/23 16/23 17/23 18/23 19/23 20/23 21/23

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Notes With battery isolator Without battery isolator

First part Second part First part Second part First part Second part

Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 01 BATTERY, ALTERNATOR AND POWER SUPPLY UNIT (with and without battery isolator) BATTERY, ALTERNATOR AND POWER SUPPLY UNIT (with battery isolator) Components: A-007 K-300 K-400 A-008 K-100 K-200 F-051 F-052 F-053 F-054 F-055 F-056 F-057 F-058 W-001 F-059 E-002 G-001 G-002 GND-001 GND-002 GND-009 GND-010 M-001 S-015 V-001 X-001 X-002 X-385 X-553 X-570

70 A 70 A 20 A 7.5 A 10 A 10 A 60 A 200 A 60 A 5A 5A

Description Battery isolator control module ( BDS ) Battery isolator relay Timer relay Engine supply box ( PDU ) Ignition Relay Engine supply relay ( +12 V K-200 ) - Engine control unit ( +12 V K-200) - Engine control unit ( +12 V K-200) - Sensor Lambda (+ 12 V Batt) - Glow plug module Maxi fuse Maxi fuse Maxi fuse Not used Jumper wire ( Shunt ) ( +12 V Batt) - Control unit memories Battery isolator switch backlighting Alternator Battery Alternator ground Starter motor ground Engine ground Cab roof ground n 2 Starter motor Battery isolator switch BDS battery isolator diode Engine - cab splitting PDU splitting Cab roof cable 2 splitting Extension splitting Kam 2 Starter motor ground splitting

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Electrical systems - Harnesses and connectors

WLAPL4S55C601J

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Electrical systems - Harnesses and connectors

BATTERY, ALTERNATOR AND POWER SUPPLY UNIT (without battery isolator) Components: A-008 K-100 K-200 F-051 F-052 F-053 F-054 F-055 F-056 F-057 F-058 W-001 G-001 G-002 GND-001 GND-002 GND-009 GND-010 M-001 X-001 X-002 X-008 X-197 X-198 X-385 X-551 X-570

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70 A 70 A 20 A 7.5 A 10 A 10 A 60 A 200 A 60 A 5A

Description Engine supply box ( PDU ) Ignition Relay Engine supply relay ( +12 V K-200 ) - Engine control unit ( +12 V K-200) - Engine control unit ( +12 V K-200) - Lambda probe ( +12 V Batt) - Glow plug module Maxi fuse Maxi fuse Maxi fuse ( +12 V Batt) - Control unit memories Jumper wire ( Shunt ) Alternator Battery Alternator ground Starter motor ground Engine ground Cab roof ground n 2 Starter motor Engine - cab splitting PDU splitting Battery isolator module connector ( BDS ) Battery isolator switch connector Battery isolator switch backlighting connector Cab roof cable 2 splitting BDS set diode connector Starter motor ground splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C602J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 02 FUSES Components: F-003 F-008 F-014 F-015 F-016

15 A 15 A 5A 15 A 15 A5

F-019

F-020 F-022 F-023 F-024 F-025 F-026 F-027 F-028 F-029 F-031 F-033 F-034 F-035 F-036 F-037 S-038 X-370 X-385

5A 10 A 10 A 5A 7.5 A 5A 3A 15 A 10 A 30 A 15 A 0.5 A 10 A 5A 10 A

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Description Fuses and relays panel ( +12 V F-056 - 200 A) - Dipped beam headlights ( +12 V F-056 - 200 A) - Flasher power supply ( +12 V F-056 - 200 A) - Brake lights ( +12 V F-056 - 200 A) - Full beam headlights ( +12 V K-001 ) - Work lights ( +12 V F-054 - 10 A) - Dashboard control unit ( ADIC ), hand brake switch, fault diagnosis socket ( +12 V 15/54 Key) - Dashboard control unit ADIC ) ( +12 V 15/54 Key) - Emergency switch ( +12 V K-002 ) - ISO socket ( +12 V K-002 ) - Position lights ( +12 V K-002 ) - Position lights ( +12 V 15/54 Key) - Clutch pedal switch ( +12 V 15/54 Key) - Engine control unit ( +12 V K-001 ) - Brake lights ( +12 V 15/54 Key) - Pneumatic seat, reverse gear alarm ( +12 V F-056 - 200 A) - Socket 25 A ( +12 V F-056 - 200 A) - Cigar lighter Not used ( +12 V 15/54 Key) - Front windscreen wiper ( +12 V F-056 - 200 A) - Lights switch ( +12 V F-056 - 200 A) - Socket 8 A Ignition switch Cab transmission power splitting Cab roof cable 2 splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C603J

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

NOTE: * : APPLIES ONLY TO ISO MARKETS

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 03 ELECTRONIC LIFT (EDC) Components: A-001 A-004 A-006 F-009 A-016 B-017 B-018 B-019 B-020 B-021 S-003 S-004 X-300 Y-005 Y-006

Description Transmission control unit ( XCM ) Electronic lift mouse ( EDC ) Fuses and relays panel ( +12 V 15/54 Key) - Electronic lift mouse ( EDC ) Electronic lift LED module Lift potentiometer panel Arms position sensor Electronic lift left draft pin Electronic lift right draft pin Radar Lift switch on the left fender Lift switch on the right fender Transmission cab splitting EDC lifting solenoid valve EDC lowering solenoid valve

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Electrical systems - Harnesses and connectors

WLAPL4S55C604J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 04 POWER TAKE-OFF, 4-WHEEL DRIVE AND DIFFERENTIAL LOCK Components: A-001 A-006 F-010 B-022 E-027 E-034 E-035 GND-011 S-008 S-010 S-011 S-012 S-013 S-055 S-056 X-300 Y-007 Y-008 Y-009

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Description Transmission control unit ( XCM ) Fuses and relays panel ( +12 V 15/54 Key) - PTO rear, differential lock backlighting, 4WD engagement, reactivity switch PTO speed sensor PTO engagement modulation switch backlighting Differential lock switch backlighting 4 WD engagement switch backlighting Ground for 40 A socket Rear PTO Switch PTO switch on the right fender PTO switch on the left fender PTO engagement modulation switch Synchronized power take-off sensing switch Differential lock switch 4 WD engagement switch Transmission cab splitting 4 WD disengagement solenoid Differential lock solenoid Rear PTO solenoid

Electrical systems - Harnesses and connectors

WLAPL4S55C605J

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

NOTE: * : APPLIES ONLY TO ISO MARKETS

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 05 AIR CONDITIONING Components: A-006 F-001 F-013 F-017 F-018 F-030 K-004 K-005 K-006 K-007 A-013 K-025 A-012 B-030 B-031 E-003 GND-005 GND-008 GND-009 GND-010 M-002 M-003 M-004 S-023 S-024 S-025 X-001 X-046 X-047 X-050 Y-013

15 A 15 A 7.5 A 20 A 20 A

Description Fuses and relays panel ( +12 V F-056 - 200 A) - Third left fan speed ( +12 V F-056 - 200 A ) - Third right fan speed ( +12 V 15/54 Key) - Air conditioning control unit ( +12 V F-056 - 200 A ) - Fourth left fan speed ( +12 V F-056 - 200 A ) - Fourth right fan speed 3rd left fan speed 3rd right fan speed 4th left fan speed 4th right fan speed Cab fuse and relay module connector Air conditioning compressor Air-conditioning control unit Frost thermostat Air conditioning temperature potentiometer Air conditioning panel illumination Fuse and relay box n 2 ground Panel ground Engine ground Cab roof ground n 2 Left fan Right fan Air-conditioning actuator Fan speed switch HVAC switch Air conditioning pressure switch on the filter Engine - cab splitting Left fan splitting Right fan splitting Cab roof main cable splitting Air conditioning compressor

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Electrical systems - Harnesses and connectors

WLAPL4S55C634J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 06 WORK LAMPS T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Components: E-004 E-005 E-006 E-007 E-008 E-009 E-010 E-011 E-037 GND-010 S-026 S-027 S-028 X-035B X-035C X-050 X-063

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Description Console Light Spot lamp Worklamp Rear Right Hand Worklamp Rear Left Hand Front right work light Front left work light Work light on front right handrail Work light on front left handrail Lights switch backlighting Cab roof ground n 2 Lights switch Door switch Work lights switch Lights jumper wire connector Lights jumper wire connector Cab roof main cable splitting Roof lights connector

Electrical systems - Harnesses and connectors

WLAPL4S55C608J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 06 WORK LAMPS T5.95 NA, T5.105 NA, T5.115 NA

Components: E-004 E-005 E-006 E-007 E-008 E-009 GND-010 S-027 S-028 X-035B X-050 X-063

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Description Console Light Spot lamp Worklamp Rear Right Hand Worklamp Rear Left Hand Front right work light Front left work light Cab roof ground n 2 Door switch Work lights switch Lights jumper wire connector Cab roof main cable splitting Roof lights connector

Electrical systems - Harnesses and connectors

WLAPL4S55C607J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 07 LIGHTS T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Components: E-012 E-013 E-014 E-015 E-016 E-017 E-018 E-019 GND-005 GND-008 GND-010 H-001 X-001 X-025 X-050 X-385

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Description Left swivel lamp Right swivel lamp Left-hand light Right-hand light Front LH light Front RH light LH tail light RH tail light Fuse and relay box n 2 ground Panel ground Cab roof ground n 2 Horn Engine - cab splitting Headlights splitting Cab roof main cable splitting Cab roof cable 2 splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C610J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 07 LIGHTS T5.95 NA, T5.105 NA, T5.115 NA

Description

Components: E-012 E-013 E-014 E-015 E-016 E-017 E-018 E-018A E-019 E-019A GND-005 GND-008 GND-010 H-001 X-001 X-025 X-050 X-385

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Left swivel lamp Right swivel lamp Left-hand light Right-hand light Front LH light Front RH light LH tail light Rear left flasher light RH tail light Right rear flasher light Fuse and relay box n 2 ground Panel ground Cab roof ground n 2 Horn Engine - cab splitting Headlights splitting Cab roof main cable splitting Cab roof cable 2 splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C609J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 08 WINDSCREEN WIPER AND ROTATING BEACONS Components: A-020 E-020 E-022 GND-005 GND-008 GND-010 J-006 J-007 M-005 M-006 M-007 M-008 M-009 S-029 S-031 S-032 X-050 X-071 X-073 X-385

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Description Front windscreen wiper timer module Rotating beacon switch backlighting Rear window wiper switch backlighting Fuse and relay box n 2 ground Panel ground Cab roof ground n 2 Rotating beacon right-hand socket Rotating beacon left-hand socket Rear window wiper Front windscreen wiper for closed window Front windscreen wiper for openable window Front wiper spray pump Rear wiper spray pump Rotating beacon switch Rear window wiper switch Front wiper and full-beam/low-beam headlight switch Cab roof main cable splitting Rotating beacon right-hand socket extension Rotating beacon left-hand socket extension Cab roof cable 2 splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C611J

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

NOTE: * : APPLIES ONLY TO ISO MARKETS

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 09 AUXILIARY SOCKETS Description

Components: A-006 F-007 F-032 E-028 E-029 GND-005 GND-008 GND-011 J-001 J-002 J-003 J-004 J-005 J-008 M-010 X-098

5A 40 A

Fuses and relays panel ( +12 V 15/54 Key) - Transmission control unit ( +12 V F-056 - 200 A) - Socket 40 A Cigar light socket backlighting Optional cigar lighter backlighting Fuse and relay box n 2 ground Panel ground Ground for 40 A socket 8 A socket Cigar Lighter Socket Optional cigar lighter socket 25 A socket 40 A socket ISO/NASO socket Pneumatic seat ISO/NASO socket extension

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Electrical systems - Harnesses and connectors

WLAPL4S55C612J

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

NOTE: * : APPLIES ONLY TO ISO MARKETS ** : APPLIES ONLY TO NAR MARKETS

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 10 BRAKE LIGHTS, LICENSE PLATE LIGHT AND THIRD SPOOL VALVE T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Components: A-006 F-042 K-008 E-025 E-026 GND-010 GND-011 S-034 S-035 S-036 X-087 X-095 X-095A X-389 Y-012

7.5 A

Description Fuses and relays panel ( +12 V 15/54 Key) - Third spool valve 3rd rear spool valve splitter (if fitted) Left license plate light on the roof Right license plate light on the roof Cab roof ground n 2 Ground for 40 A socket Left brake pedal switch Right brake pedal switch 3rd spool valve splitter switch 3rd spool valve splitter solenoid extension License plate light splitting Italian license plate light extension splitting Alarm buzzer connector 3rd spool valve splitter solenoid

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Electrical systems - Harnesses and connectors

WLAPL4S55C614J

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

NOTE: * : Italian license plate extension

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 10 BRAKE LIGHTS, LICENSE PLATE LIGHT AND THIRD SPOOL VALVE T5.95 NA, T5.105 NA, T5.115 NA

Components: A-006 F-042 7.5 A K-008 GND-011 S-034 S-035 S-036 X-087 X-389 Y-012

Description Fuses and relays panel ( +12 V 15/54 Key) - Third spool valve 3rd rear spool valve splitter (if fitted) Ground for 40 A socket Left brake pedal switch Right brake pedal switch 3rd spool valve splitter switch 3rd spool valve splitter solenoid extension Alarm buzzer connector 3rd spool valve splitter solenoid

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Electrical systems - Harnesses and connectors

WLAPL4S55C613J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 11 CAN LINE Description Diagnostic socket

Components: J-009 X-001

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Engine - cab splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C615J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 13 TRANSMISSION CONTROL (first part) Components: A-001 A-006 F-011 B-005 B-011 S-021 S-046 S-048 S-049 S-058 S-059 X-300 Y-001 Y-002 Y-003 Y-004

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Description Transmission control unit ( XCM ) Fuses and relays panel ( +12 V 15/54 Key) - Speed sensor and pressure switches Speed sensor Transmission temperature sensor Creeper unit sensing switch Gear 1 and 2 sensing switch Slow range sensing switch Medium range sensing switch Clutch pressure switch A Clutch pressure switch B Transmission cab splitting Clutch A solenoid Clutch B solenoid Clutch C solenoid Clutch D solenoid

Electrical systems - Harnesses and connectors

WLAPL4S55C616J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 14 TRANSMISSION CONTROL (second part) Components: A-001 A-002 A-006 F-002 5A F-005 5A F-006 5A K-009 B-014 E-036 GND-005 GND-006 H-005 S-001 S-002 S-051 X-001 X-300

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Description Transmission control unit ( XCM ) Clutch engagement button module Clutch engagement button module (+ 12 V F-054 - 10 A) - Transmission control unit direct positive (+ 12 V 15/54 Key) - Lever shuttle (+ 12 V 15/54 Key) - Transmission control unit Reverse gear alarm (if fitted) Clutch pedal sensor Reactivity switch backlighting Fuse and relay box n 2 ground Ground 1 of the gearbox control unit Alarm buzzer shuttle lever Clutch pedal switch Reactivity switch Engine - cab splitting Transmission cab splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C617J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 15 CONTROL PANEL (First part) Components: A-009 B-013 B-015 E-032 E-033 GND-008 S-014 S-053 S-054 X-300

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Description Dashboard control unit Accelerator pedal sensor Accelerator pedal sensor Home - enter switch backlighting Up - down switch backlighting Panel ground Low gearbox oil pressure switch Switch home - enter Up - down switch Transmission cab splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C618J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 16 CONTROL PANEL (Second part) T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Description

Components: A-009 B-023 GND-008 J-010 S-007 S-016 S-017 S-018 S-019 S-020 X-001 X-300 X-381

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Dashboard control unit Fuel level sensor Panel ground ISO Socket 11786 Differential lock warning light switch Operator present switch Brake pedals not connected switch Air filter clogged switch Handbrake Switch Handbrake indicator light switch Engine - cab splitting Transmission cab splitting Trailer brake splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C620J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 16 CONTROL PANEL (Second part) T5.95 NA, T5.105 NA, T5.115 NA

Description

Components: A-009 B-023 GND-008 J-010 S-007 S-016 S-018 S-019 S-022 X-001 X-300

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Dashboard control unit Fuel level sensor Panel ground 11786 Socket Differential lock warning light switch Operator present switch Air filter clogged switch Handbrake Switch Brake oil level switch Engine - cab splitting Transmission cab splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C619J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 17 ENGINE (First part) Components: A-006 F-004 15 A K-003 A-010 B-024 B-025 B-026 B-027 B-028 B-029 GND-009 R-001 X-001 X-949

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Description Fuses and relays panel ( +12 V F-056 - 200 A) - Fuel heating Cold starting aid Engine ECU Air temperature sensor Probe lamda Particulate pre-filter exhaust gas temperature sensor ( DPF ) Pre-catalyst exhaust gas temperature sensor Pre- and post-pressure difference sensor DPF Water in fuel sensor Engine ground Fuel heater Engine - cab splitting Engine cables 1 and 2 splitting (6-way connector)

Electrical systems - Harnesses and connectors

WLAPL4S55C621J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 18 ENGINE (Second part) Components: A-010 A-011 B-001 B-002 B-003 B-004 B-006 B-007 B-008 B-009 B-010 GND-000 M-011 M-012 R-002 R-003 R-004 R-005 S-005 X-940 X-941 Y-010 Y-011 Y-015 Y-016 Y-017

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Description Engine ECU Glow plug module connector Air pressure/temperature sensor Phase sensor Exhaust gas pressure sensor on the manifold Rail pressure sensor Fuel temperature sensor Coolant temperature sensor Fuel volume sensor Exhaust gas temperature sensor connector on the manifold Crankshaft Speed Sensor Ground via chassis EGR motor TVA valve Cylinder 1 glow plug Cylinder 2 glow plug Cylinder 3 glow plug Cylinder 4 glow plug Engine oil pressure switch Splitting cable for FTP - engine 2 (injectors) Splitting cable for FTP - engine 2 Injector, Cylinder No. 1 Injector, Cylinder No. 3 Injector, Cylinder No. 4 Injector, Cylinder No. 2 wastegate solenoid valve

Electrical systems - Harnesses and connectors

WLAPL4S55C622J1

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 19 RELAY T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Components: A-006 K-001 K-002 K-010 K-011 K-012 K-013 GND-005 X-050 X-385

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Description Fuses and relays panel Service switching Sidelights Dipped beam headlights Main Beam Headlights Dipped beam headlights switch Main beam headlights switch Fuse and relay box n 2 ground Cab roof main cable splitting Cab roof cable 2 splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C624J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 19 RELAY T5.95 NA, T5.105 NA, T5.115 NA

Components: A-006 K-001 K-002 K-010 K-011 GND-005 X-050 X-385

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Description Fuses and relays panel Service switching Sidelights Dipped beam headlights Main Beam Headlights Fuse and relay box n 2 ground Cab roof main cable splitting Cab roof cable 2 splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C623J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 20 ROOF RELAYS AND FUSES Components: A-013 F-045 15 A F-046 20 A F-047 5A F-048 15 A F-049 15 A F-050 15 A K-026 K-027 K-028 GND-010 X-160

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Description Cab fuse and relay module connector ( +12 V K-026 ) - Rear window wiper ( +12 V K-026 ) - Fan speed switch, air conditioning switch ( +12 V K-026) - Radio ( +12 V F-056 - 200 A) - Rotating beacon, ceiling light ( +12 V F-056 - 200 A) - Rear work lights ( +12 V F-056 - 200 A) - Front work lights Canopy power supply Front work lamps Rear work lamps Cab roof ground n 2 Cab power splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C625J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 21 LIGHTS AND FLASHERS CONTROL T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Components: A-014 E-021 GND-005 GND-010 H-002 H-003 H-004 S-030 S-032 S-033 X-385

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Description Flasher unit Lights switch backlighting Fuse and relay box n 2 ground Cab roof ground n 2 Radio RH speaker LH speaker Lights switch Front wiper and full-beam/low-beam headlight switch Emergency switch Cab roof cable 2 splitting

Electrical systems - Harnesses and connectors

WLAPL4S55C627J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 21 LIGHTS AND FLASHERS CONTROL T5.95 NA, T5.105 NA, T5.115 NA

Components: A-014 E-021 GND-005 GND-010 H-002 H-003 H-004 S-030 S-032 S-033 X-385

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Electrical systems - Harnesses and connectors

WLAPL4S55C626J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 22 FRONT LOADER T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Components: A-006 F-039 K-014 K-015 K-016 J-011 S-044 S-060 S-061 V-002 X-380 X-392 X-392A

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7.5 A

Description Fuses and relays panel (+ 12 V 15/54 Key) - Diverter Front loader switch (if fitted) Front loader switch (if fitted) Front loader switch (if fitted) Front loader socket Front loader joystick switches Front loader implement locking switch Front loader antidamping switch Front loader jumper wire diode Cab - front loader splitting Front loader prearrangement connector Front loader prearrangement jumper wire

Electrical systems - Harnesses and connectors

WLAPL4S55C628J

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic frame 23 ITALIAN MARKET TRAILER BRAKE VALVE Components: A-006 F-041 5A K-017 K-018 S-019 S-037 X-381 Y-014 Y-018 GND-000

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Description Fuses and relays panel ( +12 V 15/54 Key) - Trailer brake Trailer brake (where applicable) Trailer brake (where applicable) Handbrake Switch Trailer brake safety switch Trailer brake splitting Trailer brake solenoid Trailer brake solenoid Ground via chassis

Electrical systems - Harnesses and connectors

WLAPL4S55C629J

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schema TRANSMISSION CONTROL UNIT, ELECTRONIC LIFT, 4 DRIVING WHEELS, DIFFERENTIAL LOCK, POWER TAKE-OFF Components:

A-001

A-002

A-004

A-006

Table Wire harnesses Electrical schematic frame 03 (55.100) Wire harnesses Electrical schematic frame 04 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 14 (55.100) Wire harnesses Electrical schematic frame 14 (55.100) Wire harnesses Electrical schematic frame 03 (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 13 (55.100) Wire harnesses Electrical schematic frame 14 (55.100) Wire harnesses Electrical schematic frame 17 (55.100) Wire harnesses Electrical schematic frame 19 (55.100) Wire harnesses Electrical schematic frame 22 (55.100) Wire harnesses Electrical schematic frame 23 (55.100)

Description

Transmission control unit ( XCM )

Clutch engagement button module

Electronic lift mouse ( EDC )

Fuses and relays panel

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Electrical systems - Harnesses and connectors

Components: F-002

F-005

F-006

F-009

5A 5A

F-010 5A F-011 K-009

A-008 70 A K100 60 A F-057

A-016

B-005

B-014

B-017

B-018

B-019

B-020

B-021

B-022

Table 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 03 (55.100) Wire harnesses Electrical schematic frame 04 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 14 (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 03 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 14 (55.100) Wire harnesses Electrical schematic frame 03 (55.100) Wire harnesses Electrical schematic frame 03 (55.100) Wire harnesses Electrical schematic frame 03 (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)

Description ( +12 V F-054 - 10 A) - Transmission control unit direct positive ( +12 V 15/54 Key) - Lever shuttle

( +12 V 15/54 Key) - Transmission control unit

( +12 V 15/54 Key) - Electronic lift mouse ( EDC ) ( +12 V 15/54 Key) - PTO rear, differential lock backlighting, 4WD engagement, reactivity switch ( +12 V 15/54 Key) - Speed sensor and pressure switches

Reverse drive alarm

Engine supply box ( PDU )

Ignition relay.

Maxi fuse

Electronic lift LED module

Speed sensor

Clutch pedal sensor

Lift potentiometer panel

Arms position sensor

Electronic lift left draft pin

Electronic lift right draft pin

Radar

Speed sensor PTO

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Electrical systems - Harnesses and connectors

Components: J-009

M-001

S-001

S-002

S-003

S-004

S-008

S-010

S-011

S-012

S-015

S-021

S-034

S-035

S-046

S-048

S-049

S-055

S-056

Table Wire harnesses Electrical schematic frame 11 (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 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 01 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 10 (55.100) Wire harnesses Electrical schematic frame 10 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 04 (55.100) Wire harnesses Electrical schematic frame 04 (55.100)

Description Diagnostic socket

Starter motor

Lever shuttle

Clutch pedal switch

Lift switch on the left fender

Lift switch on the right fender

Rear PTO Switch

PTO switch on the right fender

PTO switch on the left fender

PTO engagement modulation switch

Battery isolator switch

Creeper unit sensing switch

Left brake pedal switch

Right brake pedal switch

G gear sensing switch

R2 gear range sensing switch

R1 gear range sensing switch

Differential lock switch

4 WD engagement switch

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Electrical systems - Harnesses and connectors

Components: S-058

S-059

X-200

X-210

X-220

X-230

X-240

Y-001

Y-002

Table Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 03 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 14 (55.100) Wire harnesses Electrical schematic frame 03 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 14 (55.100) Wire harnesses Electrical schematic frame 03 (55.100) Wire harnesses Electrical schematic frame 14 (55.100) Wire harnesses Electrical schematic frame 03 (55.100) Wire harnesses Electrical schematic frame 04 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 14 (55.100) Wire harnesses Electrical schematic frame 03 (55.100) Wire harnesses Electrical schematic frame 04 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 14 (55.100) Wire harnesses Electrical schematic frame 13 (55.100) Wire harnesses Electrical schematic frame 13 (55.100)

Description Clutch pressure switch A

Clutch pressure switch B

CN1A transmission control unit connector

CN1B transmission control unit connector

CN2 transmission control unit connector

CN3A transmission control unit connector

CN3B transmission control unit connector

Clutch A solenoid

Clutch B solenoid

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Electrical systems - Harnesses and connectors

Components: Y-003

Y-004

Y-005

Y-006

Y-007

Y-008

Y-009

Description Clutch C solenoid

Clutch D solenoid

Lifting solenoid valve EDC

Lowering solenoid valve EDC

4 WD disengagement solenoid

Differential lock solenoid

Rear PTO solenoid

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Electrical systems - Harnesses and connectors

WLAPL4S55C633J

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schema ADIC CONTROL PANEL CONTROL UNIT CODE

A-006

F-005

F-011

F-019

F-024

A-007

A-009

A-014 B-013 B-023 G-001 G-002 J-009 J-010 S-007 S-014 S-015

TABLE 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 13 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100)

DESIGNATION

Fuses and relays panel

(+ 12 V 15/54 Key) - Lever shuttle

(+ 12 V 15/54 Key) - Speed sensor and pressure switches (+ 12 V F-054 - 10 A ) - Dashboard Wire harnesses - Electrical schematic control unit ( ADIC ), hand brake switch, frame 02 (55.100) fault diagnosis socket Wire harnesses - Electrical schematic (+ 12 V K-002 ) - Position lights frame 02 (55.100) Wire harnesses - Electrical schematic Battery isolator control module ( BDS ) frame 01 (55.100) Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses Dashboard control unit ( ADIC ) - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic Flasher unit frame 21 (55.100) Wire harnesses - Electrical schematic Accelerator pedal sensor frame 15 (55.100) Wire harnesses - Electrical schematic Fuel level sensor frame 04 (55.100) Wire harnesses - Electrical schematic Alternator frame 01 (55.100) Wire harnesses - Electrical schematic Battery frame 01 (55.100) Wire harnesses - Electrical schematic Diagnostic socket frame 11 (55.100) Wire harnesses - Electrical schematic ISO 11786 socket frame 16 (55.100) Wire harnesses - Electrical schematic Differential lock warning light switch frame 16 (55.100) Wire harnesses - Electrical schematic Low gearbox oil pressure switch frame 15 (55.100) Wire harnesses - Electrical schematic Battery isolator switch frame 01 (55.100)

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Electrical systems - Harnesses and connectors

CODE S-016 S-017 S-018 S-019 S-020 S-022 S-028 S-030 S-038 S-053 S-054 B-015 K-011

TABLE 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 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 02 (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 19 (55.100)

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DESIGNATION Operator present switch Brake pedals not connected switch Air filter clogged switch Handbrake Switch Handbrake indicator light switch Brake oil level switch Work lights switch Lights switch Ignition switch Home - enter switch Up - down switch Hand Throttle High beam headlights relay

Electrical systems - Harnesses and connectors

WLAPL4S55C1001J

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire connectors - Component Diagram 00 CONNECTOR X-001 (female) - Main Harness / Engine Connection — X–001 (Male) — Engine / Cab split CONNECTOR X-001 - Main Harness / Engine Connection PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 Wire harnesses - Electrical 2 148 (N/W) X-376Diagnostic Socket X-001Main schematic frame 01 (55.100) Wire harnesses - Electrical 165 (N/W) Harness/ Engine Connection schematic frame 05 (55.100) X-091Light Control SW SP-050 Wire harnesses - Electrical 3 42 (R/G) X-012ALTERNATOR D+ schematic frame 07 (55.100) 44 (R/G) X-001Engine - Cab split Wire harnesses - Electrical X-001Main Harness/ Engine schematic frame 07 (55.100) Connection X-460ADIC CN2 Wire harnesses - Electrical 4 schematic frame 11 (55.100) 5 269 (R) X-360Brake fluid level switch Wire harnesses - Electrical 290 (R) X-001Engine - Cab split X-460ADIC CN2 X-001Main Harness/ schematic frame 14 (55.100) Wire harnesses - Electrical Engine Connection schematic frame 16 (55.100) 6 X-357Engine Intake Air Filter 272 (Y) Wire harnesses - Electrical X-001Engine - Cab split 292 (Y) schematic frame 16 (55.100) X-460ADIC CN2 X-001Main Harness/ Wire harnesses - Electrical Engine Connection schematic frame 17 (55.100) 7 299 (O/U) SP-029 X-001Main Harness/ Engine 300 (O/U) Connection X-360Brake fluid level switch X-001Engine - Cab split 8 357 (O/W) X-042A/C filter X-001Engine - Cab 470 (O/W) split X-001Main Harness/ Engine Connection X-050Cab/ Main Harness Connection 9 361 (O/U) X-042A/C filter X-001Engine - Cab 634 (O/U) split X-001Main Harness/ Engine Connection X-044Thermostat No Frost A/C 10 522 (B) X-001Main Harness/ Engine 540 (B) Connection X-410Steering Column Ground X-001Engine - Cab split X-025Bonnet lights Split 11 518 (W) X-001Main Harness/ Engine 542 (W) Connection X-050Cab/ Main Harness Connection X-001Engine - Cab split X-025Bonnet lights Split

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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 12 535 (S) 579 (S)

538 (G) 998 (G)

523 (U) 544 (U)

469 (U) 771 (U)

817 (Y) 852 (Y)

818 (G) 851 (G)

275 (TQ/W) 823 (U/W)

1004 (Y) 842 (Y)

155 (U/Y) 2 (U/Y)

21 22

X-001Engine - Cab split X-025Bonnet lights Split X-001Main Harness/ Engine Connection X-120Modulo Relays R9-R16 + Fuses F37-F40 X-001Engine - Cab split X-025Bonnet lights Split X-120Modulo Relays R9-R16 + Fuses F37-F40 X-001Main Harness/ Engine Connection X-091Light Control SW X-001Main Harness/ Engine Connection X-001Engine - Cab split X-025Bonnet lights Split X-050Cab/ Main Harness Connection X-001Main Harness/ Engine Connection X-088A/C compressor X-001Engine - Cab split SP-085 X-001Main Harness/ Engine Connection X-001Engine - Cab split S58 X-001Main Harness/ Engine Connection SP-084 X-001Engine - Cab split S60 X-001Main Harness/ Engine Connection X-450ADIC CN1 X-008BDS (Control) X-001Engine Cab split X-001Main Harness/ Engine Connection SP-150 X-008BDS (Control) X-001Engine Cab split SP-008 X-001Main Harness/ Engine Connection X-001Engine - Cab split X-002PDU split -

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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 07 (55.100) Wire harnesses - Electrical schematic frame 11 (55.100) Wire harnesses - Electrical schematic frame 14 (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)

Electrical systems - Harnesses and connectors

CONNECTOR X-001 - Main Harness / Engine Connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 23 24 25 1007 (O) 336 (O)

26 27 28

33 (U) 689 (U)

29 30 31

1248 (B/Y) 1249 (G)

32 33

1252 (R/Y) 1255 (R/Y)

1253 (R/Y) 1254 (R/Y)

SP-031 X-001Engine - Cab split X-130Modulo Fuses F1-F32 X-001Main Harness/ Engine Connection X-553KAM extension connection X-001Engine - Cab split X-001Main Harness/ Engine Connection SP-074 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-001Main Harness/ Engine Connection X-001Engine - Cab split X-937EDC17 CONNECTOR 2 SP-086 X-001Engine - Cab split SP-087 X-001Main Harness/ Engine Connection SP-086 X-001Engine - Cab split SP-087 X-001Main Harness/ Engine Connection

84142902

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PIN WIRE NUMBER NUMBER 1 2 148 (N/W) 165 (N/W)

42 (R/G) 44 (R/G)

4 5

269 (R) 290 (R)

272 (Y) 292 (Y)

299 (O/U) 300 (O/U)

357 (O/W) 470 (O/W)

361 (O/U) 634 (O/U)

522 (B) 540 (B)

518 (W) 542 (W)

CONNECTOR X-001 - Engine - Cab Split CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-376Diagnostic Socket X-001Main Harness/ Engine Connection X-937EDC17 CONNECTOR 2 X-001Engine - Cab split X-012ALTERNATOR D+ X-001Engine - Cab split SP-004 X-420Engine ground X-360Brake fluid level switch X-001Engine - Cab split X-460ADIC CN2 X-001Main Harness/ Engine Connection X-357Engine Intake Air Filter X-001Engine - Cab split X-460ADIC CN2 X-001Main Harness/ Engine Connection SP-029 X-001Main Harness/ Engine Connection X-360Brake fluid level switch X-001Engine - Cab split X-042A/C filter X-001Engine - Cab split X-001Main Harness/ Engine Connection X-050Cab/ Main Harness Connection X-042A/C filter X-001Engine - Cab split X-001Main Harness/ Engine Connection X-044Thermostat No Frost A/C X-001Main Harness/ Engine Connection X-410Steering Column Ground X-001Engine - Cab split X-025Bonnet lights split X-001Main Harness/ Engine Connection X-050Cab/ Main Harness Connection X-001Engine - Cab split X-025Bonnet lights split

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Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 12 535 (S) 579 (S)

538 (G) 998 (G)

523 (U) 544 (U)

469 (U) 771 (U)

817 (Y) 852 (Y)

818 (G) 851 (G)

275 (TQ/W) 823 (U/W)

1004 (Y) 842 (Y)

155 (U/Y) 2 (U/Y)

21 22

CONNECTOR X-001 - Engine - Cab Split CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-001Engine - Cab split X-025Bonnet lights split X-001Main Harness/ Engine Connection X-120Modulo Relays R9-R16 + Fuses F37-F40 X-001Engine - Cab split X-025Bonnet lights split SP-062 X-001Main Harness/ Engine Connection X-091Light Control SW X-001Main Harness/ Engine Connection X-001Engine - Cab split X-025Bonnet lights split X-050Cab/ Main Harness Connection X-001Main Harness/ Engine Connection X-088A/C compressor X-001Engine - Cab split SP-085 X-001Main Harness/ Engine Connection X-001Engine - Cab split S58 X-001Main Harness/ Engine Connection SP-084 X-001Engine - Cab split S60 X-001Main Harness/ Engine Connection X-450ADIC CN1 X-008BDS (Control) X-001Engine Cab split X-001Main Harness/ Engine Connection SP-150 X-008BDS (Control) X-001Engine Cab split SP-008 X-001Main Harness/ Engine Connection X-001Engine - Cab split X-002PDU split -

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Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 23 24 25 1007 (O) 336 (O)

26 27 28

33 (U) 689 (U)

29 30 31

1248 (B/Y) 1249 (G)

32 33

1252 (R/Y) 1255 (R/Y)

1253 (R/Y) 1254 (R/Y)

CONNECTOR X-001 - Engine - Cab Split CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-031 X-001Engine - Cab split X-130Modulo Fuses F1-F32 X-001Main Harness/ Engine Connection X-002PDU split X-001Engine - Cab split X-001Main Harness/ Engine Connection SP-074 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-001Main Harness/ Engine Connection X-001Engine - Cab split X-937EDC17 CONNECTOR 2 SP-086 X-001Engine - Cab split SP-087 X-001Main Harness/ Engine Connection SP-086 X-001Engine - Cab split SP-087 X-001Main Harness/ Engine Connection

84142903

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Electrical systems - Harnesses and connectors

CONNECTOR X-002 - PDU split PIN WIRE NUMBER NUMBER 1 1 (B) 26 (B) 2

25 (U/Y) 2 (U/Y)

18 (B/W) 743 (B/W)

20 (R/Y) 4 (R/Y)

21 (R/Y) 744 (R/Y)

22 (R/B) 745 (R/B)

7 8

23 (U) 41 (R/Y) 840 (R/Y)

574 (G/W) 681 (G/W)

PIN WIRE NUMBER NUMBER 1 1 (B) 2 2 (U/Y) 3

743 (B/W)

4 (R/Y)

744 (R/Y)

745 (R/B)

33 (U)

41 (R/Y)

9 10

574 (G/W) -

CONNECTOR X-002 - PDU split CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

Wire harnesses - Electrical X-892Battery Negative Stud schematic frame 01 (55.100) X-893Boost Terminal Negative SP-008 X-460ADIC CN2 X-007CAB Power Fuse X-370Power PDU-module split X-001Engine - Cab split X-002PDU split X-533ENGINE MAXI-RELAY MODULE X-002PDU split X-937EDC17 CONNECTOR 2 X-002PDU split SP-003 X-002PDU split X-937EDC17 CONNECTOR 2 X-002PDU split SP-003 X-002PDU split X-937EDC17 CONNECTOR 2 X-002PDU split X-004FUSE ENGINE 2 X-002PDU split X-937EDC17 CONNECTOR 2 X-002PDU split X-005KAM FUSE X-002PDU split X-002PDU split X-011STARTER MOTOR 50 X-002PDU split X-533ENGINE MAXI-RELAY MODULE SP-064 X-002PDU split X-049FUSE ENGINE 3 X-002PDU split CONNECTOR X-002 - PDU split CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

X-420Engine ground X-002PDU split Wire harnesses - Electrical X-001Engine - Cab split X-002PDU schematic frame 01 (55.100) split X-937EDC17 CONNECTOR 2 X-002PDU split X-937EDC17 CONNECTOR 2 X-002PDU split X-937EDC17 CONNECTOR 2 X-002PDU split X-937EDC17 CONNECTOR 2 X-002PDU split X-002PDU split X-001Engine - Cab split X-002PDU split X-011STARTER MOTOR 50 SP-064 X-002PDU split -

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Electrical systems - Harnesses and connectors

87382925

Male

87382924

Female

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Electrical systems - Harnesses and connectors

CONNECTOR X-003 - FUSE ENGINE 1 PIN WIRE NUMBER NUMBER 1 15 (R) 2 19 (R)

CONNECTOR X-003 - FUSE ENGINE 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-002 X-003FUSE ENGINE 1 X-003FUSE ENGINE 1 SP-003

84157160

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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 (R/G) 2 22 (R/B)

CONNECTOR X-004 - FUSE ENGINE 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-002 X-004FUSE ENGINE 2 X-004FUSE ENGINE 2 X-002PDU split

84157160

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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 (U)

CONNECTOR X-005 - KAM FUSE CIRCUIT REFERENCE X-005KAM FUSE X-002PDU split

84157160

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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-938Preheating device X-006Glow Plugs Power Fuse

84407991

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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-370Power Wire harnesses - Electrical schematic frame 01 (55.100) PDU-module split

84128187

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Electrical systems - Harnesses and connectors

CONNECTOR X-008 - BDS (Control) PIN WIRE NUMBER NUMBER 1 823 (U/W) 2 3

35 (B) 789 (B)

842 (Y)

PIN WIRE NUMBER NUMBER 1 823 (U/W) 2 3 4

35 (B) 789 (B) 842 (Y)

CONNECTOR X-008 - BDS (Control) CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-008BDS (Control) X-001Engine Cab split X-008BDS (Control) SP-004 SP-074 X-385Cab/ Main Harness Connection X-008BDS (Control) X-001Engine Cab split

Wire harnesses - Electrical schematic frame 01 (55.100)

CONNECTOR X-008 - BDS (Control) CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-008BDS (Control) X-001Engine Cab split X-008BDS (Control) SP-004 X-008BDS (Control) SP-004 X-008BDS (Control) X-001Engine Cab split

87745968

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-009 - PDU PIN WIRE NUMBER NUMBER A 3B (B) B 2B (B) C 816 (R)

CONNECTOR X-009 - PDU CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

X-009BDS X-010STARTER MOTOR Wire harnesses - Electrical schematic frame 01 (55.100) X-500+ Battery X-009BDS X-010STARTER MOTOR X-009PDU

84153306

816 (R)

82013012

3B (B)

84301913

2B (B)

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 01 CONNECTOR X-010 - STARTER MOTOR PIN WIRE NUMBER NUMBER 1 3B (B) 2 816 (R)

CONNECTOR X-010 - STARTER MOTOR CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-009BDS X-010STARTER MOTOR Wire harnesses - Electrical X-010STARTER MOTOR X-009PDU schematic frame 01 (55.100)

84138841

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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 (R/Y)

X-002PDU split X-011STARTER MOTOR 50

82944111

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-012 - ALTERNATOR D+ PIN WIRE NUMBER NUMBER 1 42 (R/G)

CONNECTOR X-012 - ALTERNATOR D+ CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-012ALTERNATOR D+ X-001Engine - Cab split

87687239

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-013 - Alternator PIN WIRE NUMBER NUMBER 1 822 (R)

CONNECTOR X-013 - Alternator CIRCUIT REFERENCE X-304STARTER MOTOR X-013Alternator

84153306

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-014 - Fuse Engine Main Fuse CONNECTOR X-014 - Fuse Engine Main Fuse WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 214 (R/B)

SP-001 X-014Fuse Engine Main Fuse

84407968

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-015 - Horn PIN WIRE NUMBER NUMBER 1 543 (U)

CONNECTOR X-015 - Horn CIRCUIT REFERENCE X-015Horn X-025Head-lamp/engine harness connection

87702238

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-016 - Horn PIN WIRE NUMBER NUMBER 1 524 (B)

CONNECTOR X-016 - Horn CIRCUIT REFERENCE

Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100)

X-016Horn SP-046

87702238

ELECTRICAL SCHEMATIC FRAME

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Electrical systems - Harnesses and connectors

CONNECTOR X-017 - LH corner light PIN WIRE NUMBER NUMBER A 526 (W) B 528 (B)

CONNECTOR X-017 - LH corner light CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-047 X-017LH corner light SP-046 X-017LH corner light

82003123

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Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-018 - Corner light RH. PIN WIRE NUMBER NUMBER A 525 (W) B 527 (B)

CONNECTOR X-018 - Corner light RH. CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-047 X-018Corner light RH. SP-046 X-018Corner light RH.

82003123

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Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100)

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 (B) 531 (G) 534 (S)

PIN WIRE NUMBER NUMBER A 534 (S) B 530 (B) C 531 (G)

SP-046 X-019LH front headlamp SP-048 X-019LH front headlamp X-019LH front headlamp SP-049

Wire harnesses - Electrical schematic frame 07 (55.100)

CONNECTOR X-019 - LH front headlamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-019LH front headlamp SP-049 SP-046 X-019LH front headlamp SP-048 X-019LH front headlamp

87745334

87697641

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Wire harnesses - Electrical schematic frame 07 (55.100)

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 (B) 532 (G) 533 (S)

PIN WIRE NUMBER NUMBER A 533 (S) B 529 (B) C 532 (G)

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

Wire harnesses - Electrical schematic frame 07 (55.100)

CONNECTOR X-020 - RH front headlamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-049 X-020RH front headlamp SP-046 X-020RH front headlamp SP-048 X-020RH front headlamp

87745334

87697641

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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 1112 (Y/B) 2 520 (B) 3

560 (TQ/B)

PIN WIRE NUMBER NUMBER 2 520 (B) 4

560 (TQ/B)

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

Wire harnesses - Electrical schematic frame 07 (55.100)

CONNECTOR X-021 - LH Front Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-021LH Front Lamp X-403Roof Ground 2 X-021LH Front Lamp SP-097

82000579

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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 (Y) 2

509 (B)

556 (TQ)

PIN WIRE NUMBER NUMBER 2 509 (B) 4

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

Wire harnesses - Electrical schematic frame 07 (55.100)

CONNECTOR X-022 - RH Front lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-022RH Front lamp X-403Roof Ground 2 X-022RH Front lamp SP-098

82000579

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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 (B) 2 3 4

546 (TQ/B) 547 (Y) 747 (R)

PIN WIRE NUMBER NUMBER 1 550 (B) 2 3 4

81 (U/B) 547 (Y) 747 (R)

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 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-090Flasher X-023LH Rear Lamp 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 - RH Rear Lamp PIN WIRE NUMBER NUMBER 1 521 (B) 2 3 4

557 (TQ) 564 (Y/B) 746 (R)

PIN WIRE NUMBER NUMBER 1 521 (B) 2 3 4

80 (U) 564 (Y/B) 746 (R)

CONNECTOR X-024 - RH Rear Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-024RH Rear Lamp X-400Fuse Box Wire harnesses - Electrical Ground 1 schematic frame 07 (55.100) X-024RH Rear Lamp SP-051 X-024RH Rear Lamp SP-058 SP-069 X-024RH Rear Lamp CONNECTOR X-024 - RH Rear Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-024RH Rear Lamp X-400Fuse Box Wire harnesses - Electrical Ground 1 schematic frame 07 (55.100) X-090Flasher X-024RH Rear Lamp X-024RH Rear Lamp SP-058 SP-069 X-024RH Rear Lamp

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Electrical systems - Harnesses and connectors

CONNECTOR X-025 - Bonnet lights Split / Head-lamp - engine harness connection CONNECTOR X-025 - Bonnet lights Split / Head-lamp - engine harness connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 535 (S) 536 (S)

537 (G) 538 (G)

539 (B) 540 (B)

541 (W) 542 (W)

5 6

543 (U) 544 (U)

X-001Engine - Cab split X-025Bonnet lights Split SP-049 X-025Head-lamp/engine harness connection SP-048 X-025Head-lamp/engine harness connection X-001Engine - Cab split X-025Bonnet lights Split SP-046 X-025Head-lamp/engine harness connection X-001Engine - Cab split X-025Bonnet lights Split SP-047 X-025Head-lamp/engine harness connection X-001Engine - Cab split X-025Bonnet lights Split X-015Horn X-025Head-lamp/engine harness connection X-001Engine - Cab split X-025Bonnet lights Split

87691968

Wire harnesses - Electrical schematic frame 07 (55.100) Wire harnesses - Electrical schematic frame 07 (55.100)

Bonnet lights Split

87710588

Head-lamp â&#x20AC;&#x201D; engine harness connection

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Electrical systems - Harnesses and connectors

CONNECTOR X-026 - 8A Socket PIN WIRE NUMBER NUMBER 1 726 (B) 2

637 (TQ/W)

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 (B) 2

649 (S/R)

X-027Cigar Lighter Base X-400Fuse Wire harnesses - Electrical schematic frame 09 (55.100) Box Ground 1 X-027Cigar Lighter Base SP-057

87699736

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Electrical systems - Harnesses and connectors

CONNECTOR X-028 - Cigar Lighter OPT Base CONNECTOR X-028 - Cigar Lighter OPT Base WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 648 (B) 2

650 (S/R)

X-410Steering Column Ground X-028Cigar Lighter OPT Base X-028Cigar Lighter OPT Base SP-057

87699736

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Wire harnesses - Electrical schematic frame 09 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-029 - Electrical Seat PIN WIRE NUMBER NUMBER 1 727 (B) 2

877 (W/U)

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

87699736

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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 (G/S) 2 354 (S) 3

342 (TQ/W)

349 (K)

353 (R)

CONNECTOR X-030 - Fan Speed SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-038 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

84279647

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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 (G/S) 2 437 (G/B) 4 451 (B)

CONNECTOR X-031 - A/C SW CIRCUIT REFERENCE SP-038 X-031A/C SW X-031A/C SW SP-027 X-031A/C SW X-403Roof Ground 2

87736481

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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 3 613 (O/B) 4 7

612 (R/Y) 620 (O/W)

600 (R/Y)

CONNECTOR X-032 - Beacon SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-073LH Beacon Socket/ Extension Wire harnesses - Electrical schematic frame 08 (55.100) X-032Beacon SW X-032Beacon SW SP-054 X-071RH Beacon Socket/ Extension X-032Beacon SW X-032Beacon SW SP-054

87745329

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Electrical systems - Harnesses and connectors

CONNECTOR X-033 - Beacon SW Lamp PIN WIRE NUMBER NUMBER 1 619 (Y/B) 2 606 (B)

CONNECTOR X-033 - Beacon SW Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-042 X-033Beacon SW Lamp X-403Roof Ground 2 X-033Beacon SW Lamp

84131048

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Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-034 - Lights SW PIN NUMBER 1 2 3 4 5

WIRE NUMBER 1233 1235 1236 1234 1232

1237 (L/B)

(W/R) (L/B) (L/B) (W/R) (W/U)

CONNECTOR X-034 - Lights SW CIRCUIT REFERENCE SP-053 X-034Lights SW SP-079 X-034Lights SW SP-079 X-034Lights SW SP-053 X-034Lights SW X-034Lights SW X-385Main Circuit Connection 2 SP-079 X-034Lights SW

87745329

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-035 - Lights SW Lamp PIN WIRE NUMBER NUMBER 1 1239 (Y/B) 2 1238 (B)

CONNECTOR X-035 - Lights SW Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-042 X-035Lights SW Lamp X-035Lights SW Lamp X-403Roof Ground 2

84131048

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Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (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) 3

410 (A)

409A (H)

410 (A)

SP-033 X-047RH Fan X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-035CRoof Road+Work light connection SP-1 X-939EDC17 CONNECTOR 1 X-94162 FPT interface

84153175

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Wire harnesses - Electrical schematic frame 06 (55.100) 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 3 616 (O/U) 4

598 (G/Y)

1241 (G)

1212 (G/B)

870 (G/Y)

1211 (G/B)

X-036Rear Wiper and Washer SW X-050Main Circuit Connection 1 SP-055 X-036Rear Wiper and Washer SW X-036Rear Wiper and Washer SW X-038Rear Wiper X-036Rear Wiper and Washer SW SP-013 X-036Rear Wiper and Washer SW SP-055 X-036Rear Wiper and Washer SW SP-013

87745329

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Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-037 - Rear Wiper and Washer SW Lamp CONNECTOR X-037 - Rear Wiper and Washer SW Lamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 597 (Y/B) 2

604 (B)

SP-042 X-037Rear Wiper and Washer SW Lamp X-403Roof Ground 2 X-037Rear Wiper and Washer SW Lamp

84131048

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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 (B) 2

1241 (G)

3 4 5 6

1240 (G/Y) 1210 (G/B) -

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 SP-013 X-038Rear Wiper -

87710588

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Electrical systems - Harnesses and connectors

CONNECTOR X-039 - Radio PIN NUMBER 2 4 5 6 7 9

WIRE NUMBER 643 640 641 642 644 883

(Y) (TQ/B) (TQ) (Y/B) (B) (W/G)

CONNECTOR X-039 - Radio CIRCUIT REFERENCE X-039Radio X-084LH Speaker 1 X-039Radio X-083RH Speaker 2 X-039Radio X-082RH Speaker 1 X-039Radio X-085LH Speaker 2 X-039Radio X-403Roof Ground 2 X-150Fuse &amp; Relay Module X-039Radio

84257494

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (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 (B) 2

1564 (G/B)

CONNECTOR X-040 - A/C SW LED CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-403Roof Ground 2 X-040A/C SW LED X-040A/C SW LED SP-027

84278792

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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 (U) 2

360 (S)

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 (O/W) 2

361 (O/U)

CONNECTOR X-042 - A/C filter CIRCUIT REFERENCE X-042A/C filter X-001Engine - Cab split X-042A/C filter X-001Engine - Cab split

82012083

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-043 - actuator valve A/C CONNECTOR X-043 - actuator valve A/C WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 355 (W/G) 2 3

458 (O) 459 (W/R)

460 (W/B)

462 (W/B)

Wire harnesses - Electrical X-045A/C CN X-043actuator valve schematic frame 05 (55.100) A/C X-043actuator valve A/C SP-037 X-043actuator valve A/C X-045A/C CN X-045A/C CN X-043actuator valve A/C X-043Aactuator valve A/C X-045A/C CN

84265223

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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 (G/B) 2

634 (O/U)

443 (B)

Wire harnesses - Electrical X-044Thermostat No Frost A/C X-050Cab/ Main Harness Connection schematic frame 05 (55.100) X-001Main Harness/ Engine Connection X-044Thermostat No Frost A/C X-044Thermostat No Frost A/C X-410Steering Column Ground

84136442

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Electrical systems - Harnesses and connectors

CONNECTOR X-045 - A/C CN PIN WIRE NUMBER NUMBER 2 356 (O) 3 457 (B) 6

463 (U)

460 (W/B)

459 (W/R)

462 (W/B)

464 (S)

355 (W/G)

CONNECTOR X-045 - A/C CN CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

Wire harnesses - Electrical X-045A/C CN SP-037 X-045A/C CN X-410Steering Column schematic frame 05 (55.100) Ground X-045A/C CN X-050Cab/ Main Harness Connection X-045A/C CN X-043actuator valve A/C X-043actuator valve A/C X-045A/C CN X-043Aactuator valve A/C X-045A/C CN X-045A/C CN X-050Cab/ Main Harness Connection X-045A/C CN X-043actuator valve A/C

87694702

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Electrical systems - Harnesses and connectors

CONNECTOR X-046 - LH Fan â&#x20AC;&#x201D; A/C Fan PIN WIRE NUMBER NUMBER 1 309 (S) 2 346 (TQ/W) 3 453 (B) 4

445 (R/B)

351 (G)

PIN WIRE NUMBER NUMBER 1 1 (C) 2

2 (RG)

3 4 5

7 (N) 5 (AG) 3 (RB)

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 CONNECTOR X-046 - A/C Fan CIRCUIT REFERENCE X-892Battery Negative Stud X-893Boost Terminal Negative X-001Engine - Cab split X-002PDU split X-973 X-046 SP-033 X-046 X-150Fuse &amp; Relay Module SP-043

84286809

LH Fan

84335033

A/C Fan

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-046A - LH Fan PIN WIRE NUMBER NUMBER 1 1 (C) 2

2 (RG)

3 (RB)

4 (AG)

CONNECTOR X-046A - LH Fan CIRCUIT REFERENCE X-892Battery Negative Stud X-893Boost Terminal Negative X-001Engine - Cab split X-002PDU split X-150Fuse &amp; Relay Module SP-043 X-937EDC17 CONNECTOR 2 X-002PDU split

84279647

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-047A - RH Fan PIN WIRE NUMBER NUMBER 1 308 (S) 2 348 (TQ/W) 3 449 (B) 4

364 (W)

352 (N)

PIN NUMBER 1 2 3 4 5

WIRE NUMBER 27 (S) 28 (TQ/W) 7 (N) 5 (AG) 3 (R/B)

CONNECTOR X-047A - RH Fan CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

Wire harnesses - Electrical SP-032 X-047RH Fan schematic frame 05 (55.100) SP-033 X-047RH Fan 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 CONNECTOR X-047 - A/C Fan WIRE SIZE

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 05 (55.100)

1.00H 1.00H 2.50H 2.50H 1.50H

84279647

RH Fan

84335033

A/C Fan

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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 (B) 2

1230 (Y)

1224 (TQ/W)

1225 (O/B)

1220 (G)

1231 (G/W)

Wire harnesses - Electrical X-048WIPER MOTOR TIMER schematic frame 08 (55.100) X-400Fuse Box Ground 1 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

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Electrical systems - Harnesses and connectors

CONNECTOR X-049 - FUSE ENGINE 3 PIN WIRE NUMBER NUMBER 1 716 (R/W) 2 681 (G/W)

CONNECTOR X-049 - FUSE ENGINE 3 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-002 X-049FUSE ENGINE 3 X-049FUSE ENGINE 3 X-002PDU split

84157160

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Wire harnesses - Electrical schematic frame 05 (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 1 Wire harnesses - Electrical 310 (S) SP-032 X-050Cab/ Main Harness schematic frame 05 (55.100) 354 (S) Connection Wire harnesses - Electrical X-030Fan Speed SW X-050Main schematic frame 06 (55.100) Circuit Connection 1 Wire harnesses - Electrical 2 342 (TQ/W) X-030Fan Speed SW X-050Main schematic frame 07 (55.100) 343 (TQ/W) Circuit Connection 1 Wire harnesses - Electrical SP-033 X-050Cab/ Main Harness schematic frame 08 (55.100) Connection 3 353 (R) X-030Fan Speed SW X-050Main 447 (R) Circuit Connection 1 X-050Cab/ Main Harness Connection SP-035 4 380 (G/B) X-044Thermostat No Frost A/C 84 (G/B) X-050Cab/ Main Harness Connection X-050Main Circuit Connection 1 SP-027 5 349 (K) X-030Fan Speed SW X-050Main 350 (K) Circuit Connection 1 SP-034 X-050Cab/ Main Harness Connection 6 358 (U) X-041A/C Temperature Potentiometer 463 (U) X-050Main Circuit Connection 1 X-045A/C CN X-050Cab/ Main Harness Connection 7 360 (S) X-041A/C Temperature Potentiometer 464 (S) X-050Main Circuit Connection 1 X-045A/C CN X-050Cab/ Main Harness Connection 8 440 (U) X-150Fuse &amp; Relay Module 469 (U) X-050Main Circuit Connection 1 X-050Cab/ Main Harness Connection X-001Main Harness/ Engine Connection 9 439 (O/W) X-150Fuse &amp; Relay Module 470 (O/W) X-050Main Circuit Connection 1 X-001Main Harness/ Engine Connection X-050Cab/ Main Harness Connection 10 516 (O/W) X-050Main Circuit Connection 1 517 (O/W) SP-043 X-130Modulo Fuses F1-F32 X-050Cab/ Main Harness Connection

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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 1130 (S/B) 590 (S/B)

562 (Y) 563 (Y)

1301 (O/B) 621 (O/B)

504 (W) 518 (W)

1300 (TQ/B) 505 (TQ/B)

485 (G/W) 486 (G/W)

615 (O/U) 616 (O/U)

1216 (U/Y) 1217 (U/Y)

1135 (G/B) 592 (G/B)

556 (TQ) 558 (TQ)

X-063Roof Light Connection X-050Main Circuit Connection 1 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-050Cab/ Main Harness Connection X-022RH Front lamp X-050Main Circuit Connection 1 SP-012 X-050Cab/ Main Harness Connection SP-052 X-050Cab/ Main Harness Connection X-050Main Circuit Connection 1 X-075Front Wiper Motor Openable X-069Worklamp SW W X-050Main Circuit Connection 1 X-001Main Harness/ Engine Connection X-050Cab/ Main Harness Connection SP-120 X-050Cab/ Main Harness Connection X-061Change Over SW X-050Main Circuit Connection 1 X-460ADIC CN2 X-050Cab/ Main Harness Connection SP-044 X-050Main Circuit Connection 1 X-077Rear Wiper Washer Pump X-050Cab/ Main Harness Connection X-036Rear Wiper and Washer SW X-050Main Circuit Connection 1 SP-015 X-050Cab/ Main Harness 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-050Cab/ Main Harness Connection X-022RH Front lamp X-050Main Circuit Connection 1 X-050Cab/ Main Harness Connection SP-051

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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)

Electrical systems - Harnesses and connectors

CONNECTOR X-050 - Main Circuit Connection 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 310 (S) 354 (S)

342 (TQ/W) 343 (TQ/W)

353 (R) 447 (R)

380 (G/B) 84 (G/B)

349 (K) 350 (K)

358 (U) 463 (U)

360 (S) 464 (S)

440 (U) 469 (U)

439 (O/W) 470 (O/W)

516 (O/W) 517 (O/W)

1301 (O/B) 621 (O/B)

504 (W) 518 (W)

SP-032 X-050Cab/ Main Harness Connection X-030Fan Speed SW X-050Main Circuit Connection 1 X-030Fan Speed SW X-050Main Circuit Connection 1 SP-033 X-050Cab/ Main Harness Connection X-030Fan Speed SW X-050Main Circuit Connection 1 X-050Cab/ Main Harness Connection SP-035 X-044Thermostat No Frost A/C X-050Cab/ Main Harness Connection X-050Main Circuit Connection 1 SP-027 X-030Fan Speed SW X-050Main Circuit Connection 1 SP-034 X-050Cab/ Main Harness Connection X-041A/C Temperature Potentiometer X-050Main Circuit Connection 1 X-045A/C CN X-050Cab/ Main Harness Connection X-041A/C Temperature Potentiometer X-050Main Circuit Connection 1 X-045A/C CN X-050Cab/ Main Harness Connection X-150Fuse &amp; Relay Module X-050Main Circuit Connection 1 X-050Cab/ Main Harness Connection X-001Main Harness/ Engine Connection X-150Fuse &amp; Relay Module X-050Main Circuit Connection 1 X-001Main Harness/ Engine Connection X-050Cab/ Main Harness Connection X-050Main Circuit Connection 1 SP-043 X-130Modulo Fuses F1-F32 X-050Cab/ Main Harness Connection X-386LH Rear SMV SP-097 X-050Main Circuit Connection 1 X-075Front Wiper Motor Openable X-069Worklamp SW W X-050Main Circuit Connection 1 X-001Main Harness/ Engine Connection X-050Cab/ Main Harness Connection

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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 16 485 (G/W) 486 (G/W)

615 (O/U) 616 (O/U)

1216 (U/Y) 1217 (U/Y)

29 (TQ) 558 (TQ)

X-460ADIC CN2 X-050Cab/ Main Harness Connection SP-044 X-050Main Circuit Connection 1 X-077Rear Wiper Washer Pump X-050Cab/ Main Harness Connection X-036Rear Wiper and Washer SW X-050Main Circuit Connection 1 SP-015 X-050Cab/ Main Harness Connection X-075Front Wiper Motor Openable X-050Main Circuit Connection 1 X-050Main Circuit Connection 1 SP-098 SP-051 X-050Cab/ Main Harness Connection

87736513

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Electrical systems - Harnesses and connectors

CONNECTOR X-051 - Roof Lamp 1 PIN WIRE NUMBER NUMBER 1 1098 (R/Y)

CONNECTOR X-051 - Roof Lamp 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-051Roof Lamp 1 SP-054

87691425

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Wire harnesses - Electrical schematic frame 06 (55.100) 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 (B)

CONNECTOR X-052 - Roof Lamp 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-052Roof Lamp 2 X-403Roof Ground 2

87691425

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Wire harnesses - Electrical schematic frame 06 (55.100) 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 (B)

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) Wire harnesses - Electrical schematic frame 06 (55.100)

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Electrical systems - Harnesses and connectors

CONNECTOR X-054 - Spot Lamp PIN WIRE NUMBER NUMBER 1 502 (Y/B) 2 499 (B)

CONNECTOR X-054 - Spot Lamp CIRCUIT REFERENCE X-054Spot Lamp SP-042 X-403Roof Ground 2 X-054Spot Lamp

87691950

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 06 (55.100) 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/W) 2 475 (B)

Wire harnesses - Electrical X-055RH Rear Work Lamp SP-039 X-403Roof Ground 2 X-055RH Rear schematic frame 06 (55.100) Wire harnesses - Electrical Work Lamp schematic frame 06 (55.100)

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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/W) 2 476 (B)

Wire harnesses - Electrical SP-039 X-056LH Rear Work Lamp X-056LH Rear Work Lamp X-403Roof schematic frame 06 (55.100) Wire harnesses - Electrical Ground 2 schematic frame 06 (55.100)

82012083

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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 (S) 2 474 (B)

SP-040 X-057RH Front Roof Lamp X-057RH Front Roof Lamp X-403Roof Ground 2

82012083

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Wire harnesses - Electrical schematic frame 06 (55.100) 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 (S) 2 477 (B)

Wire harnesses - Electrical X-058LH Front Roof Lamp SP-040 X-058LH Front Roof Lamp X-403Roof schematic frame 06 (55.100) Wire harnesses - Electrical Ground 2 schematic frame 06 (55.100)

82012083

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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/G) 2

511 (B)

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

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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/G) X-060LH Grab Rail Work Lamp SP-041 2 510 (B) X-403Roof Ground 2 X-060LH Grab Rail Work Lamp

84152155

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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 3 490 (Y/B) 4 505 (TQ/B)

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

87745329

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Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-062 - Change Over SW Lamp CONNECTOR X-062 - Change Over SW Lamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 492 (Y/B) 2

494 (B)

SP-042 X-062Change Over SW Lamp X-062Change Over SW Lamp X-403Roof Ground 2

84131048

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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 1135 (G/B) 2

1130 (S/B)

1099 (TQ/G)

4 5

495 (S) 513 (TQ/G)

X-063Roof Light Connection X-050Main Circuit Connection 1 X-063Roof Light Connection X-050Main Circuit Connection 1 X-150Fuse &amp; Relay Module X-063Roof Light Connection X-063Roof Light Connection SP-040 X-063Roof Light Connection SP-041

84253498

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Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-064 - Door switch PIN WIRE NUMBER NUMBER 1 487 (B)

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) Wire harnesses - Electrical schematic frame 06 (55.100)

87705127

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Electrical systems - Harnesses and connectors

CONNECTOR X-065 - Worklamp SW B1 PIN WIRE NUMBER NUMBER 1 515 (O/W)

CONNECTOR X-065 - Worklamp SW B1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-065Worklamp SW B1 SP-043

87705127

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Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-066 - Worklamp SW B2 PIN WIRE NUMBER NUMBER 1 500 (Y/B)

CONNECTOR X-066 - Worklamp SW B2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-066Worklamp SW B2 SP-042

87705127

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Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-067 - Worklamp SW HL PIN WIRE NUMBER NUMBER 1 488 (G/W)

CONNECTOR X-067 - Worklamp SW HL CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-067Worklamp SW HL SP-044

87705127

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Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-068 - Worklamp SW R PIN WIRE NUMBER NUMBER 1 1102 (W/Y)

CONNECTOR X-068 - Worklamp SW R CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-068Worklamp SW R X-150Fuse &amp; Relay Module

87705127

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Wire harnesses - Electrical schematic frame 06 (55.100) Wire harnesses - Electrical schematic frame 06 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-069 - Worklamp SW W PIN WIRE NUMBER NUMBER 1 504 (W)

CONNECTOR X-069 - Worklamp SW W CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-069Worklamp SW W X-050Main Circuit Connection 1

87705127

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Wire harnesses - Electrical schematic frame 06 (55.100) 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 1 Wire harnesses - Electrical 601 (B) X-403Roof Ground 2 X-071RH schematic frame 08 (55.100) Beacon Socket/ Extension 2 620 (O/W) X-071RH Beacon Socket/ Extension X-032Beacon SW

87699736

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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 (B) 2

613 (O/B)

X-403Roof Ground 2 X-073LH Beacon Socket/ Extension X-073LH Beacon Socket/ Extension X-032Beacon SW

87699736

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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 (B) 2

1219 (G)

1228 (O/B)

4 5

622 (U)

1215 (U/Y)

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 (B) 2

1222 (G)

621 (O/B)

4 5

624 (U)

1217 (U/Y)

X-075Front Wiper Motor Openable X-403Roof Ground 2 X-075Front Wiper Motor Openable X-385Main Circuit Connection 2 X-050Main Circuit Connection 1 X-075Front Wiper Motor Openable X-075Front Wiper Motor Openable X-385Main Circuit Connection 2 X-075Front Wiper Motor Openable X-050Main Circuit Connection 1

87710588

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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 (B) 2

617 (TQ/W)

X-076Front Wiper Washer Pump X-400Fuse Box Ground 1 X-076Front Wiper Washer Pump SP-045

87691950

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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 (B) 2

615 (O/U)

X-400Fuse Box Ground 1 X-077Rear Wire harnesses - Electrical schematic frame 08 (55.100) Wiper Washer Pump X-077Rear Wiper Washer Pump X-050Cab/ Main Harness Connection

87691950

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Electrical systems - Harnesses and connectors

CONNECTOR X-078 - 25A Socket 1 PIN WIRE NUMBER NUMBER 1 645 (N)

CONNECTOR X-078 - 25A Socket 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-07825A Socket 1 X-130Modulo Fuses F1-F32

87705127

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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 1 646 (B)

CONNECTOR X-079 - 25A Socket 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-07925A Socket 2 X-400Fuse Box Ground 1

87705127

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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 (Y/B) X-080Cigar Lighter Base Lamp SP-058

87705127

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Lamp ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 09 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-081 - Cigar Lighter OPT Lamp CONNECTOR X-081 - Cigar Lighter OPT Lamp WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 652 (Y/B)

X-081Cigar Lighter OPT Lamp SP-058

87705127

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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

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Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-083 - RH Speaker 2 PIN WIRE NUMBER NUMBER 1 640 (TQ/B)

CONNECTOR X-083 - RH Speaker 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-039Radio X-083RH Speaker 2

87691425

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Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-084 - LH Speaker 1 PIN WIRE NUMBER NUMBER 1 643 (Y)

CONNECTOR X-084 - LH Speaker 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-039Radio X-084LH Speaker 1

87705127

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Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-085 - LH Speaker 2 PIN WIRE NUMBER NUMBER 1 642 (Y/B)

CONNECTOR X-085 - LH Speaker 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-039Radio X-085LH Speaker 2

87691425

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Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-086 - Command 3째 Distributor SW CONNECTOR X-086 - Command 3째 Distributor SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 760 (Y/G)

759 (B)

X-110Modulo Relays R1-R8 + Fuses F33-F36 X-086Command 3째 Distributor SW X-086Command 3째 Distributor SW SP-023

87679493

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Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-087 - 3째 Distributor Solenoid CONNECTOR X-087 - 3째 Distributor Solenoid WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 177 (Y/U) 754 (Y/U)

1265 (B) 1266 (B)

X-110Modulo Relays R1-R8 + Fuses F33-F36 X-0873째 Distributor Solenoid X-0893rd distributor solenoid X-0873rd distributor solenoid disposition X-0873rd distributor solenoid disposition X-0893rd distributor solenoid X-40140A SOCKET ISO GROUND X-0873째 Distributor Solenoid

87736475

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Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-088 - A/C compressor PIN WIRE NUMBER NUMBER 1 576 (B) 2

771 (U)

CONNECTOR X-088 - A/C compressor CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-088A/C compressor X-420Engine ground X-088A/C compressor X-001Engine - Cab split

82012083

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Wire harnesses - Electrical schematic frame 05 (55.100)

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

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Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 09 CONNECTOR X-090 - Flasher PIN WIRE NUMBER NUMBER 2 173 (W/R) 4 181 (B) 5 6 8

168 (W/U) 171 (O/W) 170 (O/B)

PIN WIRE NUMBER NUMBER A1 736 (R) A2 1300 (TQ) A3 67 (G) A4 A5

1303 (TQ/B) 77 (Y)

A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8

738 (N/G) 723 (W/U) 735 (R) 166 (TQ) 31 (TQ/B) 739 (W/R) 81 (U/B) 80 (U) 181 (B)

C1 C2 C3 C4 C5 C6 C7 C8

CONNECTOR X-090 - Flasher CIRCUIT REFERENCE X-090Flasher SP-065 X-090Flasher X-400Fuse Box Ground 1 X-090Flasher SP-066 X-090Flasher X-450ADIC CN1 X-090Flasher X-450ADIC CN1 CONNECTOR X-090 - Flasher CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 21 (55.100)

ELECTRICAL SCHEMATIC FRAME

Wire harnesses - Electrical X-090Flasher SP-065 schematic frame 21 (55.100) X-090Flasher SP-051 X-090Flasher X-098Main/ 7 Pole Socket Extension X-090Flasher SP-050 X-090Flasher X-098Main/ 7 Pole Socket Extension X-090Flasher X-092Hazard SW X-090Flasher SP-066 X-090Flasher SP-065 X-091Light Control SW X-090Flasher X-091Light Control SW X-090Flasher X-092Hazard SW X-090Flasher X-090Flasher X-023LH Rear Lamp X-090Flasher X-024RH Rear Lamp X-090Flasher X-400Fuse Box Ground 1 -

87746018

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Electrical systems - Harnesses and connectors

87699386

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Electrical systems - Harnesses and connectors

CONNECTOR X-091 - Light Control SW PIN NUMBER 1 2 3 4

WIRE NUMBER 1214 1223 1227 1259

175 (S)

6 7

174 (G) 523 (U)

8 9 10 11 12

165 (TQ/B) 166 (TQ) 169 (W/U) 623 (U) 1231 (G/W)

1230 (Y)

(U/Y) (TQ/W) (O/B) (W/U)

PIN NUMBER 1 2 3 4

WIRE NUMBER 1214 1223 1227 1259

175 (S)

174 (G)

523 (U)

8 9 10 11 12

31 (TQ/B) 166 (TQ) 169 (W/U) 623 (U) 1231 (G/W)

1230 (Y)

(U/Y) (TQ/W) (O/B) (W/U)

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-385Cab/ Main Harness 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 SP-050 X-091Light Control SW SP-051 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

Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100)

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-385Cab/ Main Harness Connection X-120Modulo Relays R9-R16 + Fuses F37-F40 X-091Light Control SW X-120Modulo Relays R9-R16 + Fuses F37-F40 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 SP-066 X-091Light Control SW X-091Light Control SW SP-056 X-091Light Control SW X-048WIPER MOTOR TIMER X-091Light Control SW X-048WIPER MOTOR TIMER

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Wire harnesses - Electrical schematic frame 21 (55.100) Wire harnesses - Electrical schematic frame 08 (55.100)

Electrical systems - Harnesses and connectors

87691878

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Electrical systems - Harnesses and connectors

CONNECTOR X-092 - Hazard SW PIN WIRE NUMBER NUMBER 1 693 (L/W) 2 3

172 (W/R) 710 (R)

4 5 6 7

182 164 167 163

PIN NUMBER 2 3 6 7

(W/R) (W/U) (TQ/B) (TQ)

WIRE NUMBER 737 739 738 740

(R) (W/R) (N/G) (B)

CONNECTOR X-092 - Hazard SW CIRCUIT REFERENCE X-130Modulo Fuses F1-F32 X-092Hazard SW X-092Hazard SW SP-065 X-130Modulo Fuses F1-F32 X-092Hazard SW X-092Hazard SW SP-065 X-092Hazard SW SP-066 SP-050 X-092Hazard SW X-092Hazard SW SP-051 CONNECTOR X-092 - Hazard SW CIRCUIT REFERENCE SP-065 X-092Hazard SW X-092Hazard SW X-090Flasher X-090Flasher X-092Hazard SW X-092Hazard SW X-400Fuse Box Ground 1

84289727

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 21 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-093 - LH Stop PIN NUMBER 1 2 3 4

WIRE NUMBER 729 705 748 749

(N) (O) (R) (U/W)

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 Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-094 - RH Stop PIN NUMBER 1 2 3 4

WIRE NUMBER 742 734 750 844

(N) (O) (R) (U/Y)

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

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-095 - Licence Plate Light CONNECTOR X-095 - Licence Plate Light WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1109 (Y) 1203 (Y) 2

1110 (B) 1204 (B)

X-095ALicence plate X-095Licence plate light Italia Split (trim sx) SP-012 X-095Licence Plate Light X-095ALicence plate X-095Licence plate light Italia Split (trim sx) SP-022 X-095Licence Plate Light

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Wire harnesses - Electrical schematic frame 10 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-095A - Licence plate light CONNECTOR X-095A - Licence plate light WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1109 (Y) 2

1110 (B)

X-095ALicence plate X-095Licence plate light Italia Split (trim sx) X-095ALicence plate X-095Licence plate light Italia Split (trim sx)

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Wire harnesses - Electrical schematic frame 10 (55.100)

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 (Y/B) 2 762 (B)

SP-042 X-096LH License Plate Lamp Wire harnesses - Electrical schematic frame 10 (55.100) X-096LH License Plate Lamp X-403Roof Ground 2

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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 (Y/B) 2 763 (B)

SP-042 X-097RH License Plate Lamp Wire harnesses - Electrical schematic frame 10 (55.100) X-097RH License Plate Lamp X-403Roof Ground 2

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Electrical systems - Harnesses and connectors

CONNECTOR X-098 - Main/ 7 Pole Socket Extension CONNECTOR X-098 - Main/ 7 Pole Socket Extension WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 183 (TQ/B) 566 (Y)

569 (B) 717 (B)

179 (TQ) 732 (G)

702 (Y/B) 731 (N)

730 (R) 765 (R)

700 (Y) 733 (B)

Wire harnesses - Electrical SP-050 X-098Main/ 7 Pole Socket schematic frame 09 (55.100) Extension X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-098Main/ 7 Pole Socket Extension X-400Fuse Box Ground 1 X-099Trailer Socket ISO X-098Interconnect Transmission / Trailer Socket SP-051 X-098Main/ 7 Pole Socket Extension X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-098Main/ 7 Pole Socket Extension SP-058 X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO SP-069 X-098Main/ 7 Pole Socket Extension X-098Main/ 7 Pole Socket Extension X-130Modulo Fuses F1-F32 X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO

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Electrical systems - Harnesses and connectors

CONNECTOR X-098 - Main/ 7 Pole Socket Extension WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 566 (Y) 77 (Y)

569 (B) 717 (B)

67 (G) 732 (G)

702 (Y/B) 731 (N)

730 (R) 765 (R)

700 (Y) 735 (B)

Wire harnesses - Electrical X-099Trailer Socket ISO schematic frame 09 (55.100) X-098Interconnect Transmission / Trailer Socket X-090Flasher X-098Main/ 7 Pole Socket Extension X-098Main/ 7 Pole Socket Extension X-400Fuse Box Ground 1 X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-090Flasher X-098Main/ 7 Pole Socket Extension X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-098Main/ 7 Pole Socket Extension SP-058 X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO SP-069 X-098Main/ 7 Pole Socket Extension X-098Main/ 7 Pole Socket Extension X-130Modulo Fuses F1-F32 X-090Flasher SP-065

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Electrical systems - Harnesses and connectors

CONNECTOR X-099 - Trailer Socket PIN WIRE NUMBER NUMBER 1 566 (Y)

717 (B)

732 (G)

731 (N)

730 (R)

733 (B)

PIN WIRE NUMBER NUMBER 1 566 (Y)

717 (B)

732 (G)

731 (N)

730 (R)

733 (B)

CONNECTOR X-099 - Trailer Socket ISO CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-099Trailer Socket ISO X-098Interconnect Transmission / Trailer Socket X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO

Wire harnesses - Electrical schematic frame 09 (55.100)

CONNECTOR X-099 - Trailer Socket CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-099Trailer Socket ISO X-098Interconnect Transmission / Trailer Socket X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO X-098Interconnect Transmission / Trailer Socket X-099Trailer Socket ISO

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Wire harnesses - Electrical schematic frame 09 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 10 CONNECTOR X-100 - Safety switch A pin 2 PIN WIRE NUMBER NUMBER 1 103 (W)

CONNECTOR X-100 - Safety switch A pin 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-011 X-100Safety switch A pin 2

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 11 PLUG CONNECTOR X-110 - Module relay R1-R8 + fuses F33-F36 PLUG CONNECTOR X-110 - Module relay R1-R8 + fuses F33-F36 CONNECCABLE CIRCUIT DIAGRAM REFERENCE ELECTRICAL CIRCUIT DIAGRAM TOR PIN NUMBER NUMBER 33 A 663 (U) SP-025 X-110 module relay R1-R8 + fuses Wire harnesses - Electrical schematic frame 02 (55.100) F33-F36 33B 656 (S/R) X-110 module relay R1-R8 + fuses F33-F36 Wire harnesses - Electrical schematic frame 03 (55.100) SP-057 35 A 712 (N) SP-070 X-110 module relay R1-R8 + fuses Wire harnesses - Electrical schematic frame 04 (55.100) F33-F36 35B 1226 (O/B) X-110 module relay R1-R8 + fuses F33-F36 Wire harnesses - Electrical schematic frame 05 (55.100) SP-052 36 A 677 (U) SP-025 X-110 module relay R1-R8 + fuses Wire harnesses - Electrical schematic frame 09 (55.100) F33-F36 36B 1261 (L/B) X-110 module relay R1-R8 + fuses F33-F36 Wire harnesses - Electrical X-385 Cab/ main wiring harness connection schematic frame 10 (55.100) Wire harnesses - Electrical R1_30 572 (U) SP-025 X-110 module relay R1-R8 + fuses schematic frame 10 (55.100) F33-F36 Wire harnesses - Electrical R1_85 283 (B) X-110 module relay R1-R8 + fuses F33-F36 schematic frame 13 (55.100) X-400 fusebox earth 1 Wire harnesses - Electrical R1_86 287 (N) SP-070 X-110 module relay R1-R8 + fuses schematic frame 14 (55.100) F33-F36 Wire harnesses - Electrical R1_87 126 (N) X-110 module relay R1-R8 + fuses F33-F36 schematic frame 17 (55.100) SP-072 Wire harnesses - Electrical R2_30 570 (U) X-110 module relay R1-R8 + fuses F33-F36 schematic frame 19 (55.100) SP-025 Wire harnesses - Electrical R2_85 571 (B) X-110 module relay R1-R8 + fuses F33-F36 schematic frame 19 (55.100) SP-023 Wire harnesses - Electrical R2_86 1258 (W/R) X-110 module relay R1-R8 + fuses F33-F36 schematic frame 22 (55.100) X-385 Cab/ main wiring harness connection Wire harnesses - Electrical R2_87 696 (W) X-110 module relay R1-R8 + fuses F33-F36 schematic frame 23 (55.100) SP-071 R3_30 1244 (R) X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 R3_85 1248 (B/Y) X-110 module relay R1-R8 + fuses F33-F36 X-001 Main wiring harness/ engine connection R3_86 1243 (N) X-110 module relay R1-R8 + fuses F33-F36 SP-070 R3_87 1246 (R/Y) X-110 module relay R1-R8 + fuses F33-F36 SP-087 R4_30 466 (U) X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 R4_85 367 (B) X-110 module relay R1-R8 + fuses F33-F36 SP-023 R4_86 467 (K) SP-034 X-110 module relay R1-R8 + fuses F33-F36 R4_87 351 (G) X-110 module relay R1-R8 + fuses F33-F36 X-046 Fan left R5_30 448 (U) X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36

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Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-110 - Module relay R1-R8 + fuses F33-F36 CABLE CIRCUIT DIAGRAM REFERENCE ELECTRICAL CIRCUIT DIAGRAM NUMBER

CONNECTOR PIN NUMBER R5_85 368 (B) R5_86

468 (K)

R5_87

352 (N)

R6_30

372 (U)

R6_85

442 (B)

R6_86

370 (R)

R6_87

445 (R/B)

R7_30

373 (U)

R7_85

362 (B)

R7_86

371 (R)

R7_87

364 (W)

R8_30

756 (N/S)

R8_85

760 (Y/G)

R8_86

758 (N/S)

R8_87

177 (Y/U)

X-110 module relay R1-R8 + fuses F33-F36 SP-023 SP-034 X-110 module relay R1-R8 + fuses F33-F36 X-110 module relay R1-R8 + fuses F33-F36 X-047 Fan right X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 X-110 module relay R1-R8 + fuses F33-F36 SP-023 X-110 module relay R1-R8 + fuses F33-F36 SP-035 X-110 module relay R1-R8 + fuses F33-F36 X-046 Fan left X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 X-110 module relay R1-R8 + fuses F33-F36 SP-023 SP-035 X-110 module relay R1-R8 + fuses F33-F36 X-110 module relay R1-R8 + fuses F33-F36 X-047 Fan right X-110 module relay R1-R8 + fuses F33-F36 SP-119 X-110 module relay R1-R8 + fuses F33-F36 X-086 Command 3Â° distributor switch X-110 module relay R1-R8 + fuses F33-F36 SP-119 X-110 module relay R1-R8 + fuses F33-F36 X-0873Â° Distributor solenoid valve

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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 10 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 12 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

CONNECTOR X-120 - Modulo Relays R9-R16 + Fuses F37-F40 CONNECTOR X-120 - Modulo Relays R9-R16 + Fuses F37-F40 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 37A 674 (U) 37B

637 (TQ/W)

39A

257 (N)

39B

692 (O)

R10_30

568 (O)

R10_85

567 (B)

R10_86

175 (S)

R10_87

583 (S/W)

R11_30

565 (O/W)

R11_85

575 (B)

R11_86

1600 (G)

R11_87

997 (G/W)

R12_30

583 (S/W)

X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-025 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-0268A Socket X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-070 SP-073 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-130Modulo Fuses F1-F32 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-023 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-091Light Control SW X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-130Modulo Fuses F1-F32 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-023 SP-100 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40

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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_85 584 (B) R12_86

585 (TQ/B)

R12_87A

579 (S)

R12_87

590 (S/B)

R13_30

997 (G/W)

R13_85

581 (B)

R13_86

586 (TQ/B)

R13_87A

998 (G)

R13_87

592 (G/B)

R14_30

593 (O/B)

R14_85

578 (O/B)

R14_86

253 (B/W)

R14_87

711 (G/W)

SP-023 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-120 X-001Main Harness/ Engine Connection X-120Modulo Relays R9-R16 + Fuses F37-F40 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-050Cab/ Main Harness 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-050Cab/ Main Harness Connection X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-073 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-022 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-323FRONT LOADER 2 SWITCHES X-120Modulo Relays R9-R16 + Fuses F37-F40 X-392FRONT LOADER READY

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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 R15_30 594 (O/U) R15_85

587 (O/U)

R15_86

782 (TQ/B)

R15_87

713 (S)

R16_30

595 (O/W)

R16_85

588 (O/W)

R16_86

797 (B/Y)

R16_87

714 (U)

R9_30

843 (W/U)

R9_85

83 (W)

R9_86

232 (W/U)

R9_87

1262 (U/Y)

X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-073 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-022 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-323FRONT LOADER 2 SWITCHES X-120Modulo Relays R9-R16 + Fuses F37-F40 X-380Front Loader Disposition X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-073 X-120Modulo Relays R9-R16 + Fuses F37-F40 SP-022 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-317FRONT LOADER 1 SWITCH 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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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 13 PLUG CONNECTOR X-130 - Module fuses F1-F32 CONNECCABLE TOR PIN NUMBER NUMBER 1A 375 (G) 1B 466 (U) 2A 2B

848 (U) 187 (U/W)

3A 3B

662 (U) 568 (O)

4A 4B

1245 (U) 1244 (R)

5A 5B

76 (N) 105 (O/W)

6A 6B

1056 (N) 188 (O/B)

7A 7B

1242 (N) 1250 (Y)

8A 8B

676 (U) 710 (R)

9A 9B 10A 10B 11A 11B 12 A 12B 13A 13B

866 (N) 11C (B/Y) 1148 (N) 189 (S/U) 82 (N) 417 (W) 913 (N) 912 (N/S) 374 (N) 448 (U)

14A 14B 15A 15B

217 (N) 1267 (N/W) 289 (U) 565 (O/W)

16A 16B

683 (N) 517 (O/W)

PLUG CONNECTOR X-130 - Module fuses F1-F32 POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

SP-096 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 SP-074 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-200XCM CN1-A X-130 Module fuses F1-F32 SP-025 X-130 Module fuses F1-F32 X-120 module relay R9-R16 + fuses F37-F40 X-130 Module fuses F1-F32 SP-024 X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 X-130 Module fuses F1-F32 SP-070 X-130 Module fuses F1-F32 X-318 Powershuttle lever SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-200XCM CN1-A SP-070 X-130 Module fuses F1-F32 X-50140A BUSH ISO 1 X-130 Module fuses F1-F32 SP-025 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-092 hazard flasher SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-068 SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-020 SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-417 X-130 Module fuses F1-F32 SP-070 X-130 Module fuses F1-F32 SP-119 SP-025 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-018 X-130 Module fuses F1-F32 SP-025 X-130 Module fuses F1-F32 X-120 module relay R9-R16 + fuses F37-F40 SP-072 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-050cab/ main wiring harness connection

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Electrical systems - Harnesses and connectors

CONNECTOR PIN NUMBER 17A 17B 18A 18B

CABLE NUMBER 471 381 446 372

19A 19B 20A 20B 22 A 22B

32 (U) 305 (R) 687 (N) 297 (O) 664 (N) 693 (L/W)

23 A 23B

699 (W) 700 (Y)

24 A 24B 25 A 25B 26 A

697 (W) 703 (Y) 698 (W) 701 (Y/B) 679 (S)

26B

1136 (U/Y)

27 A 27B

680 (N) 336 (O)

28 A 28B 29 A 29B 30 A 30B

695 (N) 990 (O) 682 (N) 635 (W/U) 444 (U) 373 (U)

31 A 31B

685 (U) 645 (N)

32 A 32B

1065 (U) 921 (U)

(N) (O) (U) (U)

PLUG CONNECTOR X-130 - Module fuses F1-F32 POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

X-130 Module fuses F1-F32 SP-070 X-130 Module fuses F1-F32 SP-037 X-130 Module fuses F1-F32 SP-096 X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 X-130 Module fuses F1-F32 SP-074 X-130 Module fuses F1-F32 SP-030 SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-029 X-130 Module fuses F1-F32 SP-070 X-130 Module fuses F1-F32 X-092 Hazard flasher X-130 Module fuses F1-F32 SP-071 X-098 Main/7-pin bush extension X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-071 X-130 Module fuses F1-F32 SP-012 X-130 Module fuses F1-F32 SP-071 X-130 Module fuses F1-F32 SP-058 X-512 Ignition switch 50 X-130 Module fuses F1-F32 X-319 CLUTCH PEDAL SWITCH X-130 Module fuses F1-F32 SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-001 Main wiring harness/ engine connection X-130 Module fuses F1-F32 SP-072 SP-067 X-130 Module fuses F1-F32 SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-118 SP-096 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 X-130 Module fuses F1-F32 SP-024 X-07825A Bush 1 X-130 module fuses F1-F32 SP-024 X-130 Module fuses F1-F32 X-50140A BUSH ISO 1 X-130 Module fuses F1-F32

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Electrical systems - Harnesses and connectors

CONNECCABLE TOR PIN NUMBER NUMBER 1A 375 (G) 1B 466 (U) 2A 2B

848 (U) 187 (U/W)

3A 3B

662 (U) 568 (O)

4A 4B

1245 (U) 1244 (R)

5A 5B

76 (N) 105 (O/W)

6A 6B

1056 (N) 188 (O/B)

7A 7B

1242 (N) 1250 (Y)

8A 8B 9A 9B 10A 10B 11A 11B 12 A 12B 13A 13B

676 (U) 710 (R) 866 (N) 11C (B/Y) 1148 (N) 189 (S/U) 82 (N) 417 (W) 913 (N) 912 (N/S) 374 (N) 448 (U)

14A 14B 15A 15B

217 (N) 1267 (N/W) 289 (U) 565 (O/W)

16A 16B

683 (N) 517 (O/W)

17A 17B 18A

471 (N) 381 (O) 446 (U)

PLUG CONNECTOR X-130 - Module fuses F1-F32 POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

SP-096 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 SP-074 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-200XCM CN1-A X-130 Module fuses F1-F32 SP-025 X-130 Module fuses F1-F32 X-120 module relay R9-R16 + fuses F37-F40 X-130 Module fuses F1-F32 SP-024 X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 X-130 Module fuses F1-F32 SP-070 X-130 Module fuses F1-F32 X-318 Powershuttle lever SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-200XCM CN1-A SP-070 X-130 Module fuses F1-F32 X-50140A BUSH ISO 1 X-130 Module fuses F1-F32 SP-025 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-065 SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-068 SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-020 SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-417 X-130 Module fuses F1-F32 SP-070 X-130 Module fuses F1-F32 SP-119 SP-025 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 SP-070 X-130 Module fuses F1-F32 SP-018 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-025 X-130 Module fuses F1-F32 X-120 module relay R9-R16 + fuses F37-F40 SP-072 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-050cab/ main wiring harness connection X-130 Module fuses F1-F32 SP-070 X-130 Module fuses F1-F32 SP-037 X-130 Module fuses F1-F32 SP-096

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Electrical systems - Harnesses and connectors

CONNECCABLE TOR PIN NUMBER NUMBER 18B 372 (U) 19A 19B 20A 20B 22 A 22B 23 A 23B

32 (U) 305 (R) 687 (N) 297 (O) 664 (N) 693 (L/W) 699 (W) 700 (Y)

24 A 24B 25 A 25B 26 A

697 (W) 703 (Y) 698 (W) 701 (Y/B) 679 (S)

26B

1136 (U/Y)

27 A 27B

680 (N) 336 (O)

28 A 28B 29 A 29B 30 A 30B

695 (N) 990 (O) 682 (N) 635 (W/U) 444 (U) 373 (U)

31 A 31B

685 (U) 645 (N)

32 A 32B

1065 (U) 921 (U)

PLUG CONNECTOR X-130 - Module fuses F1-F32 POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 X-130 Module fuses F1-F32 SP-074 X-130 Module fuses F1-F32 SP-030 SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-029 X-130 Module fuses F1-F32 SP-070 X-130 Module fuses F1-F32 SP-066 X-130 Module fuses F1-F32 SP-071 X-098 Main/7-pin bush extension X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-071 X-130 Module fuses F1-F32 SP-012 X-130 Module fuses F1-F32 SP-071 X-130 Module fuses F1-F32 SP-058 X-512 Ignition switch 50 X-130 Module fuses F1-F32 X-319 CLUTCH PEDAL SWITCH X-130 Module fuses F1-F32 SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-001 Main wiring harness/ engine connection X-130 Module fuses F1-F32 SP-072 SP-067 X-130 Module fuses F1-F32 SP-070 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 SP-118 SP-096 X-130 Module fuses F1-F32 X-130 Module fuses F1-F32 X-110 module relay R1-R8 + fuses F33-F36 X-130 Module fuses F1-F32 SP-024 X-07825A Bush 1 X-130 module fuses F1-F32 SP-024 X-130 Module fuses F1-F32 X-50140A BUSH ISO 1 X-130 Module fuses F1-F32

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 14 CONNECTOR X-140 - Modulo Relays R17-R24 + Fuses F41-F44 CONNECTOR X-140 - Modulo Relays R17-R24 + Fuses F41-F44 CONNECTOR X-140 - Modulo Relays R17-R24 + Fuses F41-F44 CONNECTOR X-140 - Modulo Relays R17-R24 + Fuses F41-F44 CONNECTOR X-140 - Modulo Relays R17-R24 + Fuses F41-F44 CONNECTOR X-140 - Modulo Relays R17-R24 + Fuses F41-F44 CONNECTOR X-140 - Modulo Relays R17-R24 + Fuses F41-F44 PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 41A X-140Modulo Relays R17-R24 + Wire harnesses - Electrical 923 (N/S) Fuses F41-F44 SP-113 schematic frame 02 (55.100) Wire harnesses - Electrical 41B X-140Modulo Relays R17-R24 + 778 (N) schematic frame 03 (55.100) Fuses F41-F44 SP-070 Wire harnesses - Electrical R17_30 X-140Modulo Relays R17-R24 + 787 (N/S) schematic frame 04 (55.100) Fuses F41-F44 SP-113 Wire harnesses - Electrical R17_85 X-140Modulo Relays R17-R24 + 1009 (G) Fuses F41-F44 X-358Handbrake SW schematic frame 05 (55.100) Wire harnesses - Electrical R17_86 775 (N/S) SP-113 X-140Modulo Relays schematic frame 09 (55.100) R17-R24 + Fuses F41-F44 Wire harnesses - Electrical R17_87 X-140Modulo Relays R17-R24 + 779 (Y/U) schematic frame 10 (55.100) Fuses F41-F44 SP-111 Wire harnesses - Electrical R18_30 924 (N/S) SP-113 X-140Modulo Relays schematic frame 13 (55.100) R17-R24 + Fuses F41-F44 Wire harnesses - Electrical R18_85 X-140Modulo Relays R17-R24 + 755 (B) schematic frame 14 (55.100) Fuses F41-F44 SP-023 Wire harnesses - Electrical R18_86 X-140Modulo Relays R17-R24 + 927 (N/W) schematic frame 17 (55.100) Fuses F41-F44 X-381Main/ Trailer Wire harnesses - Electrical Brake Connection schematic frame 19 (55.100) R18_87 X-140Modulo Relays R17-R24 + 922 (Y/U) Wire harnesses - Electrical Fuses F41-F44 SP-111 schematic frame 22 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100)

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Wire connectors - Component diagram 15 PLUG CONNECTOR X-150 - fuse &amp; relay module CONNECCABLE TOR PIN NUMBER NUMBER 1A 669 (W) 1B 660 (TQ/B) 2A 2B

670 (W) 661 (TQ/W)

3A 3B 4A 4B 5A 5B 6A 6B R1_30

671 (W) 871 (R/Y) 659 (R) 883 (W/G) 657 (R) 1161 (G/S) 672 (R) 675 (Y/G) 661 (TQ/W)

R1_85

666 (B)

R1_86

1102 (W/Y)

R1_87 R2_30 R2_85

887 (TQ/W) 658 (W) 665 (B)

R2_86 R2_87 R3_30 R3_85

1104 (W/O) 673 (R) 3 (W/U) 438 (B)

R3_86

439 (O/W)

R3_87

440 (U)

R4_30

660 (TQ/B)

R4_85

667 (B)

R4_86 R4_87

1101 (G/W) 1099 (TQ/G)

PLUG CONNECTOR X-150 - fuse & relay module POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

Wire harnesses - Electrical SP-060 X-150 Fuse &amp; relay module X-150 Fuse &amp; relay module X-150 Fuse schematic frame 20 (55.100) &amp; relay module X-150 Fuse &amp; relay module SP-060 X-150 Fuse &amp; relay module X-150 Fuse &amp; relay module X-150 Fuse &amp; relay module SP-060 X-150 Fuse &amp; relay module SP-054 SP-059 X-150 Fuse &amp; relay module X-150 Fuse &amp; Relay module X-039Radio SP-059 X-150 Fuse &amp; relay module SP-038 X-150 Fuse &amp; relay module X-150 Fuse &amp; relay module SP-059 X-150 Fuse &amp; relay module SP-055 X-150 Fuse &amp; relay module X-150 Fuse &amp; relay module X-150 Fuse &amp; relay module X-403 Roof earth 2 X-068 Work light switch R X-150 Fuse &amp; relay module X-150 Fuse &amp; relay module SP-039 SP-060 X-150 Fuse &amp; relay module X-150 Fuse &amp; relay module X-403 Roof earth 2 SP-043 X-150 Fuse &amp; relay module X-150 Fuse &amp; relay module SP-059 X-150 Fuse &amp; Relay module SP-043 X-150 Fuse &amp; relay module X-403 Roof earth 2 X-150 Fuse &amp; relay module X-050 Main power circuit Connection 1 X-150 Fuse &amp; relay module X-050 Main power circuit Connection 1 X-150 Fuse &amp; relay module X-150 Fuse &amp; relay module X-403 Roof earth 2 X-150 Fuse &amp; relay module X-150 Fuse &amp; relay module SP-044 X-150 Fuse &amp; relay module X-063 Roof lighting system connection

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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 A Wire harnesses - Electrical 668 (W) X-160Main Power Connection schematic frame 20 (55.100) 768 (U) SP-060 SP-036 X-160Cab Power/ Main Harness Connection

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 19 CONNECTOR X-197 - BDS SW PIN WIRE NUMBER NUMBER 3 37 (S/U) 4 5 6

38 (R) 790 (R) 806 (Y)

CONNECTOR X-197 - BDS SW CIRCUIT REFERENCE X-197BDS SW X-385Main Circuit Connection 2 X-197BDS SW SP-075 SP-075 X-197BDS SW X-197BDS SW X-385Main Circuit Connection 2

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-198 - BDS SW Lamp PIN WIRE NUMBER NUMBER 1 36 (Y/B) 2 39 (B)

CONNECTOR X-198 - BDS SW Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-198BDS SW Lamp SP-042 X-198BDS SW Lamp X-403Roof Ground 2

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-199 - Range R2 PIN WIRE NUMBER NUMBER 1 78 (O) 2

94 (TQ/W)

CONNECTOR X-199 - Range R2 CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

X-300MAIN Connection X-199Range Wire harnesses - Electrical schematic frame 13 (55.100) R2 SP-005 X-199Range R2

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 20 CONNECTOR X-200 - XCM CN1-A PIN WIRE NUMBER NUMBER 1 188 (O/B) 2 3 4

46 (R/G)

124 (B/W)

425 (L)

435 (G/W)

390 (Y/B)

9 10 11

156 (N/B) 50 (R)

130 (G/W)

13 14

187 (U/W)

15 16 17 18 19

854 (Y) 853 (G) 220 (B)

20 21 22 23 24 25

216 (B/Y) 85 (B) 221 (B)

222 (B)

CONNECTOR X-200 - XCM CN1-A CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-130Modulo Fuses F1-F32 X-200XCM CN1-A X-200XCM CN1-A X-300Trasmission/ Main Harness Connection X-200XCM CN1-A X-300Trasmission/ Main Harness Connection X-200XCM CN1-A X-300Trasmission/ Main Harness Connection X-200XCM CN1-A X-300Trasmission/ Main Harness Connection X-319CLUTCH PEDAL SW X-200XCM CN1-A X-200XCM CN1-A X-320Gear Lever X-200XCM CN1-A X-300Trasmission/ Main Harness Connection X-200XCM CN1-A X-300Trasmission/ Main Harness Connection X-130Modulo Fuses F1-F32 X-200XCM CN1-A SP-083 X-200XCM CN1-A SP-082 X-200XCM CN1-A X-200XCM CN1-A X-280XCM GROUND 1 SP-068 X-200XCM CN1-A X-200XCM CN1-A SP-009 X-200XCM CN1-A X-280XCM GROUND 1 X-200XCM CN1-A X-280XCM GROUND 1

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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 2 136 (S/W) 3 4

114 (U/R) 52 (Y/R)

109 (S/B)

48 (R)

108 (U/Y)

8 9

113 (S/B) 117 (S/G)

133 (Y/G)

11 12 13 14

207 (W/G) 386 (Y/G) 69 (U/R)

15 16 17 18 19

98 (TQ/W) 116 (G/B) 1200 (N/Y)

20 21

118 (N/W) 885 (O/B)

22 23 24 25 26 27 28

749 (U/W) 844 (U/Y) 122 (S/U) 73 (O/W)

29 30 31 32 33

22B (R/U) 26B (R/W) 1201 (B/W)

CONNECTOR X-210 - XCM CN1-B CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-210XCM CN1-B X-300Trasmission/ Main Harness 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-300Trasmission/ Main Harness Connection X-210XCM CN1-B X-300Trasmission/ Main Harness Connection X-210XCM CN1-B X-318Shuttle Lever X-210XCM CN1-B X-318Shuttle Lever X-210XCM CN1-B X-300Trasmission/ Main Harness Connection X-210XCM CN1-B SP-006 X-326EDC MOUSE X-210XCM CN1-B X-210XCM CN1-B X-300Trasmission/ Main Harness Connection X-326EDC MOUSE X-210XCM CN1-B X-300Trasmission/ Main Harness Connection X-210XCM CN1-B X-093LH Stop X-210XCM CN1-B X-210XCM CN1-B X-094RH Stop X-210XCM CN1-B SP-124 X-210XCM CN1-B X-300Trasmission/ Main Harness Connection X-210XCM CN1-B SP-016 X-210XCM CN1-B SP-010 X-210XCM CN1-B X-300Trasmission/ Main Harness Connection -

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 22 CONNECTOR X-220 - XCM CN2 PIN NUMBER 1 2 3 4

WIRE NUMBER 127 (G/W)

131 (G/Y)

6 7 8 9 10 11

91 (K)

83 (W)

13 14 15 16 17 18 19

89 (O/U)

20 21

223 (B)

22 23 24

90 (K/B)

92 (K/W)

224 (B)

CONNECTOR X-220 - XCM CN2 CIRCUIT REFERENCE X-220XCM CN2 X-300Trasmission/ Main Harness Connection X-220XCM CN2 X-300Trasmission/ Main Harness Connection X-534EDC LED PANEL X-220XCM CN2 X-120Modulo Relays R9-R16 + Fuses F37-F40 X-220XCM CN2 X-534EDC LED PANEL X-220XCM CN2 X-220XCM CN2 X-280XCM GROUND 1 X-534EDC LED PANEL X-220XCM CN2 X-534EDC LED PANEL X-220XCM CN2 X-220XCM CN2 X-280XCM GROUND 1

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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 13 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 23 CONNECTOR X-230 - XCM CN3-A PIN NUMBER 1 2 3 4

WIRE NUMBER 028 (W) 60 (S)

57 (O)

115 (TQ)

369 (W)

8 9

146 (K/W) 201 (O/U)

10 11 12 13

149 (U) 147 (O/TQ) 389 (TQ/W)

14 15

74 (U/Y) 382 (W)

465 (S/U)

211 (G)

18 19 20

321 (N/B)

21 22 23 24 25 26

1111 (O) 773 (TQ) 64 (S/R)

CONNECTOR X-230 - XCM CN3-A CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-230XCM CN3-A SP-417 X-230XCM CN3-A X-300Trasmission/ Main Harness Connection X-230XCM CN3-A X-300Trasmission/ Main Harness Connection X-326EDC MOUSE X-230XCM CN3-A X-322CLUTCH PEDAL SENSOR X-230XCM CN3-A X-230XCM CN3-A X-320Gear Lever X-351PTO SOFT START SW X-230XCM CN3-A X-230XCM CN3-A X-320Gear Lever X-230XCM CN3-A X-320Gear Lever X-230XCM CN3-A X-318Shuttle Lever X-230XCM CN3-A SP-008 X-230XCM CN3-A X-318Shuttle Lever X-230XCM CN3-A X-300Trasmission/ Main Harness Connection X-230XCM CN3-A X-300Trasmission/ Main Harness Connection X-349Fender PTO SW RH X-230XCM CN3-A X-230XCM CN3-A SP-021 X-3744WD SW X-230XCM CN3-A X-230XCM CN3-A X-300Trasmission/ Main Harness Connection

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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 (O/B) 2

56 (B/W)

426 (B/Y)

450 (G/B)

5 6 7 8 9

195 (Y)

10 11 12 13 14

359 (N/L) 197 (O/B)

15 16 17

196 (U/G)

209 (N/G)

200 (N/W)

20 21 22

58 (O/U)

23 24 25 26 27 28 29 30 31 32 33 34

363 157 383 508 766 190 218

(S) (S) (W/U)

(R/G) (B) (S/U) (S/U)

CONNECTOR X-240 - XCM CN3-B CIRCUIT REFERENCE X-240XCM CN3-B X-300Trasmission/ Main Harness Connection X-240XCM CN3-B X-300Trasmission/ Main Harness Connection X-240XCM CN3-B X-300Trasmission/ Main Harness Connection X-240XCM CN3-B X-300Trasmission/ Main Harness Connection X-240XCM CN3-B X-300Trasmission/ Main Harness Connection X-350Rear PTO SW X-240XCM CN3-B X-240XCM CN3-B X-300Trasmission/ Main Harness Connection X-240XCM CN3-B X-300Trasmission/ Main Harness Connection X-240XCM CN3-B X-300Trasmission/ Main Harness Connection X-240XCM CN3-B X-300Trasmission/ Main Harness Connection X-240XCM CN3-B X-300Trasmission/ Main Harness Connection X-350Rear PTO SW X-240XCM CN3-B X-313REACTIVITY SW X-240XCM CN3-B X-240XCM CN3-B X-318Shuttle Lever SP-026 X-240XCM CN3-B SP-017 X-240XCM CN3-B X-313REACTIVITY SW X-240XCM CN3-B SP-020 X-240XCM CN3-B

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 25 CONNECTOR X-250 - Home-Enter SW PIN WIRE NUMBER NUMBER 1 240 (K/B) 2

234 (B)

235 (B)

241 (W/B)

CONNECTOR X-250 - Home-Enter SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical X-250Home-Enter SW X-450ADIC schematic frame 15 (55.100) CN1 X-250Home-Enter SW X-410Steering Column Ground X-250Home-Enter SW X-410Steering Column Ground X-250Home-Enter SW X-450ADIC CN1

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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 (N/B) 2 236 (B) 3

237 (B)

243 (U/B)

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 15 (55.100) Column Ground X-260UP-Down SW X-410Steering Column Ground X-260UP-Down SW X-450ADIC CN1

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 27 CONNECTOR X-270 - Home-Enter SW Lamp PIN WIRE NUMBER NUMBER 1 238 (B) 2

244 (Y)

CONNECTOR X-270 - Home-Enter SW Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical X-270Home-Enter SW Lamp schematic frame 15 (55.100) X-410Steering Column Ground SP-012 X-270Home-Enter SW Lamp

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 28 CONNECTOR X-280 - XCM GROUND 1 PIN WIRE NUMBER NUMBER 1 220 (B) 2

221 (B)

222 (B)

223 (B)

224 (B)

CONNECTOR X-280 - XCM GROUND 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-200XCM CN1-A X-280XCM GROUND 1 X-200XCM CN1-A X-280XCM GROUND 1 X-200XCM CN1-A X-280XCM GROUND 1 X-220XCM CN2 X-280XCM GROUND 1 X-220XCM CN2 X-280XCM GROUND 1

84153309

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 29 CONNECTOR X-290 - UP-Down SW Lamp PIN WIRE NUMBER NUMBER 1 239 (B) 2

245 (Y)

CONNECTOR X-290 - UP-Down SW Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-290UP-Down SW Lamp X-410Steering Column Ground SP-012 X-290UP-Down SW Lamp

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Wire harnesses - Electrical schematic frame 15 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-295 - Diode PIN WIRE NUMBER NUMBER 1 903 (R/G) 2

908 (G)

CONNECTOR X-295 - Diode CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

X-392Front loader ready Wire harnesses - Electrical predisposition JUMPER X-295Diode schematic frame 22 (55.100) X-295Diode SA1

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 30 PLUG CONNECTOR X-300 - Transmission / Main wiring harness Connection PLUG CONNECTOR X-300 - Transmission / Main wiring harness Connection CONNECCABLE POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM TOR PIN NUMBER NUMBER 1 Wire harnesses - Electrical 47 (B/O) X-364 CLUTCH A SOLENOID VALVE schematic frame 03 (55.100) 55 (O/B) X-300 Main connection Wire harnesses - Electrical X-240XCM CN3-B X-300 Transmission/ schematic frame 04 (55.100) Main wiring harness connection Wire harnesses - Electrical 2 51 (B/W) X-365 CLUTCH B SOLENOID VALVE schematic frame 13 (55.100) 56 (B/W) X-300 Main connection Wire harnesses - Electrical X-240XCM CN3-B X-300 Transmission/ schematic frame 14 (55.100) Main wiring harness connection 3 102 (O/W) X-300 Main connection X-522 safety switch Wire harnesses - Electrical schematic frame 15 (55.100) 73 (O/W) B Pin 2 Wire harnesses - Electrical X-210XCM CN1-B X-300 Transmission/ schematic frame 16 (55.100) Main wiring harness connection Wire harnesses - Electrical 4 100 (TQ/W) X-300 Transmission/ Main wiring harness schematic frame 16 (55.100) 865 (TQ/W) connection SP-006 5

45 (R/G) 46 (R/G)

49 (R) 50 (R)

425 (L) 456 (L)

426 (B/Y) 461 (B/Y)

435 (G/W) 481 (G/W)

450 (G/B) 479 (G/B)

61 (B) 63 (B)

SP-005 X-300 Main connection X-364 CLUTCH A SOLENOID VALVE X-300 Main connection X-200XCM CN1-A X-300 Transmission/ Main wiring harness connection X-365 CLUTCH B SOLENOID VALVE X-300 Main connection X-200XCM CN1-A X-300 Transmission/ Main wiring harness connection X-200XCM CN1-A X-300 Transmission/ Main wiring harness connection X-806 CLUTCH C SOLENOID VALVE X-300 Main connection X-240XCM CN3-B X-300 Transmission/ Main wiring harness connection X-806 CLUTCH C SOLENOID VALVE X-300 Main connection X-200XCM CN1-A X-300 Transmission/ Main wiring harness connection X-807 CLUTCH D SOLENOID VALVE X-300 Main connection X-240XCM CN3-B X-300 Transmission/ Main wiring harness connection X-807 CLUTCH D SOLENOID VALVE X-300 Main connection SP-009 X-300 Transmission/ Main wiring harness connection SP-007 X-300 Main connection

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Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-300 - Transmission / Main wiring harness Connection CABLE POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM NUMBER

CONNECTOR PIN NUMBER 12 58 (O/U) 59 (O/U) 13

60 (S) 72 (S)

029 (W) 54 (W)

101 (O/B) 885 (O/B)

16 17

57 (O) 78 (O)

18 19 20

68 (U/R) 69 (U/R)

465 (S/U) 82 (S/TQ)

179 (N/G) 209 (N/G)

124 (B/W) 125 (B/W)

264 (N) 303 (N)

271 (U) 295 (U)

176 (B/O) 197 (O/B)

161 (S/U) 162 (S/TQ)

117 (S/G) 121 (S/G)

X-240XCM CN3-B X-300 Transmission/ Main wiring harness connection X-309 Wheel speed X-300 Main connection X-230XCM CN3-A X-300 Transmission/ Main wiring harness connection X-300 Main connection X-301 gear G X-300 Transmission/ Main wiring harness connection SP-417 X-300 Main connection SP-011 X-300 Main connection X-383 safety switch A Pin 1 X-300 Transmission/ Main wiring harness connection X-210XCM CN1-B X-230XCM CN3-A X-300 Transmission/ Main wiring harness connection X-300 Main connection X-199 range R2 X-316 Transm. oil temp. X-300 Main connection X-210XCM CN1-B X-300 Transmission/ Main wiring harness connection X-230XCM CN3-A X-300 Transmission/ Main wiring harness connection SP-070 X-130 Module fuses F1-F32 SP-051 X-098Main/ 7-pin receptacle extension X-240XCM CN3-B X-300 Transmission/ Main wiring harness connection X-200XCM CN1-A X-300 Transmission/ Main wiring harness connection X-334EDC SOLENOID VALVE LIFT X-300 Main connection X-354 Level sensor X-300 Main connection X-450ADIC CN1 X-300 Transmission/ Main wiring harness connection X-340DIFF-LOCK STATUS SWITCH X-300 Main connection X-450ADIC CN1 X-300 Transmission/ Main wiring harness connection X-344 Rear PTO shaft solenoid valve X-300 Main connection X-240XCM CN3-B X-300 Transmission/ Main wiring harness connection X-300 Transmission/ Main wiring harness connection SP-124 X-385 Main power circuit connection 2 SP-053 X-210XCM CN1-B X-300 Transmission/ Main wiring harness connection X-332 Right traction sensor X-300 Main connection

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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 13 (55.100) Wire harnesses - Electrical schematic frame 14 (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)

Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-300 - Transmission / Main wiring harness Connection CABLE POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM NUMBER

CONNECTOR PIN NUMBER 29 1200 (N/Y) 137 (N/Y) 30

1201 (B/W) 139 (B/W)

1202 (B/Y)

139 (R) R (R)

127 (G/W) 128 (G/W)

131 (G/Y) 132 (G/Y)

1095 (S/U) 182 (S/U)

133 (Y/G) 134 (Y/G)

123 (S/TQ) 872 (S/U)

38 39 40

64 (S/R) 79 (S/R)

191 (Y) 195 (Y)

192 (U/G) 196 (U/G)

210 (G) 211 (G)

X-210XCM CN1-B X-300 Transmission/ Main wiring harness connection X-333Radar X-300 Main connection X-210XCM CN1-B X-300 Transmission/ Main wiring harness connection X-300 Transmission/ Main wiring harness connection X-460ADIC CN2 X-300 Transmission/ main wiring harness connection SP-068 X-300 Transmission/ Main wiring harness connection X-460ADIC CN2 X-353Power Off 1 X-300 Main connection X-220XCM CN2 X-300 Transmission/ Main wiring harness connection X-334EDC SOLENOID VALVE RAISE X-300 Main connection X-220XCM CN2 X-300 Transmission/ Main wiring harness connection X-335EDC SOLENOID VALVE LOWERING X-300 Main connection SP-020 X-300 Transmission/ Main wiring harness connection X-092Warnblinker SW SP-065 X-210XCM CN1-B X-300 Transmission/ Main wiring harness connection X-331 Left traction sensor X-300 Main connection X-300 Main connection X-331 Left traction sensor X-300 Transmission/ Main wiring harness connection SP-124 X-230XCM CN3-A X-300 Transmission/ Main wiring harness connection X-300 Main connection X-308 range R1 X-300 Main connection X-343DIFFSPERRE SOLENOID VALVE X-240XCM CN3-B X-300 Transmission/ Main wiring harness connection X-300 Main connection X-3422WD SOLENOID VALVE X-240XCM CN3-B X-300 Transmission/ Main wiring harness connection X-352 Earth speed switch X-300 Main connection X-230XCM CN3-A X-300 Transmission/ Main wiring harness connection -

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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 13 (55.100) Wire harnesses - Electrical schematic frame 14 (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)

Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-300 - Transmission / Main wiring harness Connection CABLE POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM NUMBER

CONNECTOR PIN NUMBER 45 135 (S/W) 136 (S/W)

199 (N/W) 200 (N/W)

129 (G/W) 130 (G/W)

266 (B) 268 (B)

49 50

10 (B) 1260 (B)

X-328 Lifting shaft position sensor X-300 Main connection X-210XCM CN1-B X-300 Transmission/ Main wiring harness connection X-341PTO shaft speed sensor X-300 Main connection X-240XCM CN3-B X-300 Transmission/ Main wiring harness connection X-335EDC SOLENOID VALVE LOWERING X-300 Main connection X-200XCM CN1-A X-300 Transmission/ Main wiring harness connection SP-028 X-300 Transmission/ Main wiring harness connection X-354 Level sensor X-300 Main connection SP-088 X-300 Main connection X-300 Transmission/ Main wiring harness connection X-40140A RECEPTACLE ISO EARTH

87708541

Wire harnesses - Electrical schematic frame 03 (55.100) Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 13 (55.100) Wire harnesses - Electrical schematic frame 14 (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)

Transmission / Main wiring harness connection

87708538

Main connection

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Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-301 - gear G CONNECCABLE NUMBER TOR PIN NUMBER 1 72 (S) 2 86 (TQ/W)

PLUG CONNECTOR X-301 - gear G POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

X-300 Main connection X-301 gear G Wire harnesses - Electrical schematic frame 13 (55.100) SP-005 X-301 gear G

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Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-303 - Diff. lock SW Light PLUG CONNECTOR X-303 - Diff. lock SW Light CABLE NUMBER POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

CONNECTOR PIN NUMBER 1 178 (B) 2 1184 (Y)

X-303Diff. lock SW Light SP-022 SP-012 X-303Diff. lock SW Light

84131048

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-304 - STARTER CONNECCABLE NUMBER TOR PIN NUMBER 1 822 (R)

PLUG CONNECTOR X-304 - STARTER POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

X-304STARTER X-013 Alternator

84138841

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-308 - range R1 CONNECCABLE NUMBER TOR PIN NUMBER 1 79 (S/R) 2

95 (TQ/W)

PLUG CONNECTOR X-308 - range R1 POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

X-300 Main connection X-308 range Wire harnesses - Electrical R1 schematic frame 13 (55.100) SP-005 X-308 range R1

87691973

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Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-309 - Wheel speed PLUG CONNECTOR X-309 - Wheel speed CABLE NUMBER POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

CONNECTOR PIN NUMBER 1 1126 (W) 2 59 (O/U) 3

66 (B)

SP-011 X-309 Wheel speed X-309 Wheel speed X-300 Main connection X-309 Wheel speed SP-007

84806091

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 31 CONNECTOR X-313 - REACTIVITY SW PIN WIRE NUMBER NUMBER 1 190 (S/U) 2 3 4

227 (S/U) 858 (S/U) 157 (S)

CONNECTOR X-313 - REACTIVITY SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-313REACTIVITY SW X-240XCM CN3-B SP-020 X-313REACTIVITY SW X-313REACTIVITY SW SP-020 X-313REACTIVITY SW X-240XCM CN3-B

87745329

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-314 - 4WD SW Lamp PIN WIRE NUMBER NUMBER 1 138 (B) 2 1183 (Y)

CONNECTOR X-314 - 4WD SW Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-3144WD SW Lamp SP-022 SP-012 X-3144WD SW Lamp

84131048

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-316 - Trans oil Temp PIN WIRE NUMBER NUMBER A 20U (B) B 68 (U/R)

CONNECTOR X-316 - Trans oil Temp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-316Trans oil Temp SP-007 X-316Trans oil Temp X-300MAIN Connection

82012093

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-317 - FRONT LOADER 1 SWITCH CONNECTOR X-317 - FRONT LOADER 1 SWITCH WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 798 (O/W) 2

797 (B/Y)

Wire harnesses - Electrical SP-073 X-317FRONT LOADER 1 schematic frame 22 (55.100) SWITCH X-120Modulo Relays R9-R16 + Fuses F37-F40 X-317FRONT LOADER 1 SWITCH

82012083

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Electrical systems - Harnesses and connectors

CONNECTOR X-318 - Shuttle Lever PIN WIRE NUMBER NUMBER 1 1114 (TQ) 2 207 (W/G) 3

386 (Y/G)

383 (W/U)

105 (O/W)

382 (W)

376 (W/U)

8 9 10 11

65 (B) 389 (TQ/W)

70 (S)

71 (U/Y)

CONNECTOR X-318 - Shuttle Lever CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-006 X-318Shuttle Lever X-210XCM CN1-B X-318Shuttle Lever X-210XCM CN1-B X-318Shuttle Lever X-240XCM CN3-B X-318Shuttle Lever X-130Modulo Fuses F1-F32 X-318Shuttle Lever 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

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-319 - CLUTCH PEDAL SW CONNECTOR X-319 - CLUTCH PEDAL SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1136 (U/Y) 2

390 (Y/B)

376 (W/U)

70 (S)

X-319CLUTCH PEDAL SW X-130Modulo 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

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 32 CONNECTOR X-320 - Gear Lever PIN NUMBER 1 2 3 4

WIRE NUMBER 147 149 156 146

(O/TQ) (U) (N/B) (K/W)

CONNECTOR X-320 - Gear Lever CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

X-230XCM CN3-A X-320Gear Lever Wire harnesses - Electrical X-230XCM CN3-A X-320Gear Lever schematic frame 14 (55.100) X-200XCM CN1-A X-320Gear Lever X-230XCM CN3-A X-320Gear Lever

84149200

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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 (W/B) 3

84 (O)

11 (TQ)

5 6

225 (W)

7 8

88 (B) 75 (B)

Wire harnesses - Electrical schematic frame 15 (55.100) X-321Foot Pedal Sensor SW X-450ADIC CN1 X-050Main Circuit Connection 1 SP-027 X-460ADIC CN2 X-321Foot Pedal Sensor SW X-321Foot Pedal Sensor SW X-450ADIC CN1 X-321Foot Pedal Sensor SW SP-028 X-321Foot Pedal Sensor SW SP-028

87702265

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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 (B) 2

369 (W)

1121 (TQ)

X-322CLUTCH PEDAL SENSOR SP-009 X-322CLUTCH PEDAL SENSOR X-230XCM CN3-A SP-006 X-322CLUTCH PEDAL SENSOR

84062580

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-323 - FRONT LOADER 2 SWITCHES CONNECTOR X-323 - FRONT LOADER 2 SWITCHES WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 782 (TQ/B)

253 (B/W)

233 (O/W)

247 (O/W)

X-120Modulo Relays R9-R16 + Fuses Wire harnesses - Electrical F37-F40 X-323FRONT LOADER 2 schematic frame 22 (55.100) SWITCHES X-120Modulo Relays R9-R16 + Fuses F37-F40 X-323FRONT LOADER 2 SWITCHES SP-073 X-323FRONT LOADER 2 SWITCHES SP-073 X-323FRONT LOADER 2 SWITCHES

87715977

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Electrical systems - Harnesses and connectors

CONNECTOR X-324 - Hand Throttle PIN WIRE NUMBER NUMBER 2 226 (R) 3 231 (B) 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 15 (55.100) X-324Hand Throttle X-460ADIC CN2

87694694

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Electrical systems - Harnesses and connectors

CONNECTOR X-326 - EDC MOUSE PIN WIRE NUMBER NUMBER A 114 (U/R) B

113 (S/B)

C D E

159 (O) 120 (B) 118 (N/W)

F G

11A (B/Y) 116 (G/B)

115 (TQ)

CONNECTOR X-326 - EDC MOUSE CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-326EDC MOUSE X-210XCM CN1-B X-326EDC MOUSE X-210XCM CN1-B 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

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Wire harnesses - Electrical schematic frame 03 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-327 - EDC POT PANEL PIN WIRE NUMBER NUMBER 3 109 (S/B) 4

52 (Y/R)

5 6 7

158 (O) 160 (B) 108 (U/Y)

48 (R)

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

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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 (B) 2

135 (S/W)

857 (TQ/W)

X-328Rock Shaft Position Sensor SP-007 X-328Rock Shaft Position Sensor X-300MAIN Connection SP-005 X-328Rock Shaft Position Sensor

84062580

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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 (R/U) 2 11B (B/Y) 3 110 (R/W)

X-329Fender SW EDC LH SP-016 SP-068 X-329Fender SW EDC LH X-329Fender SW EDC LH SP-010

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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 (R/U) 2 11D (B/Y) 3 26A (R/W)

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

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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 (B) 2 134 (Y/G) 3

123 (S/TQ)

CONNECTOR X-331 - Left Draft Sensor CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-092Hazard SW SP-051 X-331Left Draft Sensor X-300MAIN Connection X-300MAIN Connection X-331Left Draft Sensor

84806091

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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 (B) 2 121 (S/G) 3

162 (S/TQ)

Wire harnesses - Electrical SP-007 X-332Right Draft Sensor X-332Right Draft Sensor X-300MAIN schematic frame 03 (55.100) Connection X-385Main Circuit Connection 2 SP-053

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Electrical systems - Harnesses and connectors

CONNECTOR X-333 - Radar PIN WIRE NUMBER NUMBER 1 139 (B/W) 2 3

1089 (B) 1202 (B/Y)

137 (N/Y)

CONNECTOR X-333 - Radar CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

Wire harnesses - Electrical X-300Trasmission/ Main Harness schematic frame 03 (55.100) Connection X-460ADIC CN2 X-333Radar SP-088 X-300Trasmission/ Main Harness Connection SP-068 X-333Radar X-300MAIN Connection

87712738

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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 (B/W) 2

128 (G/W)

X-334EDC RAISE SOLENOID X-300MAIN Connection X-334EDC RAISE SOLENOID X-300MAIN Connection

84607243

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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 (G/W) 2

132 (G/Y)

X-335EDC LOWER SOLENOID X-300MAIN Connection X-335EDC LOWER SOLENOID X-300MAIN Connection

84607243

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Wire harnesses - Electrical schematic frame 03 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 34 CONNECTOR X-340 - DIFF LOCK STATUS SWITCH CONNECTOR X-340 - DIFF LOCK STATUS SWITCH PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 1172 (W) X-340DIFF LOCK STATUS SWITCH Wire harnesses - Electrical schematic frame 16 (55.100) SP-011 Wire harnesses - Electrical 2 schematic frame 16 (55.100) 3 4 271 (U) X-340DIFF LOCK STATUS SWITCH X-300MAIN Connection

87687242

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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 (S/U) 2 199 (N/W) 3

856 (B)

Wire harnesses - Electrical X-092Hazard SW SP-065 X-341PTO Speed Sensor X-300MAIN schematic frame 04 (55.100) Connection X-341PTO Speed Sensor SP-007

84806091

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Electrical systems - Harnesses and connectors

CONNECTOR X-342 - 2WD SOLENOID PIN WIRE NUMBER NUMBER 1 192 (U/G) 2

1090 (B)

CONNECTOR X-342 - 2WD SOLENOID CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-300MAIN Connection X-3422WD SOLENOID X-3422WD SOLENOID SP-088

87691973

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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 (Y) 2

1091 (B)

X-300MAIN Connection X-343DIFF LOCK SOLENOID X-343DIFF LOCK SOLENOID SP-088

82012083

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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 1 179 (N/G) 2

176 (B/O)

Wire harnesses - Electrical SP-051 X-098Main/ 7 Pole Socket schematic frame 04 (55.100) Extension X-344Rear PTO Solenoid X-300MAIN Connection

84152155

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Electrical systems - Harnesses and connectors

CONNECTOR X-347 - FENDER PTO SWITCH LEFT CONNECTOR X-347 - FENDER PTO SWITCH LEFT WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1120 (S/U) 2

1122 (R/G)

1123 (O)

X-347FENDER PTO SWITCH LEFT Wire harnesses - Electrical schematic frame 04 (55.100) SP-020 X-347FENDER PTO SWITCH LEFT X-349Fender PTO SW RH X-347FENDER PTO SWITCH LEFT SP-021

87691928

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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 (R/G) 2

321 (N/B)

1010 (O)

X-347FENDER PTO SWITCH LEFT Wire harnesses - Electrical 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

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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 (S/U) 2 359 (N/L) 3

363 (S)

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

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-351 - PTO SOFT START SW CONNECTOR X-351 - PTO SOFT START SW WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 201 (O/U) 2

1118 (S/U)

Wire harnesses - Electrical X-351PTO SOFT START SW schematic frame 04 (55.100) X-230XCM CN3-A SP-020 X-351PTO SOFT START SW

87745322

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Electrical systems - Harnesses and connectors

CONNECTOR X-352 - Ground Speed Switch CONNECTOR X-352 - Ground Speed Switch WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 212 (TQ/W) 2 210 (G)

X-352Ground Speed Switch SP-005 X-352Ground Speed Switch X-300MAIN Connection

82012083

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-353 - Power Off 1 PIN WIRE NUMBER NUMBER 1 R (R)

CONNECTOR X-353 - Power Off 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-353Power Off 1 X-300MAIN Connection

82944111

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Wire harnesses - Electrical schematic frame 15 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-354 - Fuel Level Sensor PIN WIRE NUMBER NUMBER 1 268 (B) 2

264 (N)

CONNECTOR X-354 - Fuel Level Sensor CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-354Fuel Level Sensor X-300MAIN Connection X-354Fuel Level Sensor X-300MAIN Connection

82012083

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Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-355 - Seat SW PIN WIRE NUMBER NUMBER 1 267 (B) 2 263 (G)

CONNECTOR X-355 - Seat SW CIRCUIT REFERENCE SP-028 X-355Seat SW X-450ADIC CN1 X-355Seat SW

82012083

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 16 (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 (O/U) 2 270 (S)

SP-029 X-356Brakes not latched SW Wire harnesses - Electrical schematic frame 16 (55.100) X-356Brakes not latched SW X-450ADIC CN1

87695582

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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 (Y) 2

1174 (B)

X-357Engine X-001Engine X-357Engine X-420Engine

Intake Air Filter - Cab split Intake Air Filter ground

84607243

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Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-358 - Handbrake SW PIN WIRE NUMBER NUMBER 1 1008 (B) 2 849 (R) 3 4 5

274 (R) 1009 (G)

PIN WIRE NUMBER NUMBER 1 2 849 (R) 3 4 5

274 (R) -

CONNECTOR X-358 - Handbrake SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-358Handbrake SW SP-023 X-358Handbrake SW X-460ADIC CN2 SP-030 X-358Handbrake SW X-140Modulo Relays R17-R24 + Fuses F41-F44 X-358Handbrake SW

Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100)

CONNECTOR X-358 - Handbrake SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-358Handbrake SW X-460ADIC CN2 SP-030 X-358Handbrake SW -

82867472

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Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100)

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-381Trailer Brake-CAB split

82944111

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Wire harnesses - Electrical schematic frame 16 (55.100)

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 1 Wire harnesses - Electrical 300 (O/U) X-360Brake fluid level switch schematic frame 16 (55.100) X-001Engine - Cab split Wire harnesses - Electrical 2 269 (R) X-360Brake fluid level switch schematic frame 16 (55.100) X-001Engine - Cab split

82012083

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Electrical systems - Harnesses and connectors

CONNECTOR X-362 - FUEL HEATER PIN WIRE NUMBER NUMBER 1 2 3 1247 (B) 4

1251 (R/Y)

CONNECTOR X-362 - FUEL HEATER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-362FUEL HEATER X-420Engine ground X-362FUEL HEATER SP-086

84546837

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Wire harnesses - Electrical schematic frame 17 (55.100)

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

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Wire harnesses - Electrical schematic frame 23 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-364 - CLUTCH A SOLENOID CONNECTOR X-364 - CLUTCH A SOLENOID WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 45 (R/G) 2

47 (B/O)

X-364CLUTCH A SOLENOID X-300MAIN Connection X-364CLUTCH A SOLENOID X-300MAIN Connection

82012083

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-365 - CLUTCH B SOLENOID CONNECTOR X-365 - CLUTCH B SOLENOID WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 49 (R) 2

51 (B/W)

X-365CLUTCH B SOLENOID X-300MAIN Connection X-365CLUTCH B SOLENOID X-300MAIN Connection

84152155

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-368 - Creeper PIN WIRE NUMBER NUMBER 1 82 (S/TQ) 2 97 (TQ/W)

CONNECTOR X-368 - Creeper CIRCUIT REFERENCE SP-070 X-130Modulo Fuses F1-F32 SP-005 X-368Creeper

84152155

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-369 - REACTIVITY SW LAMP CONNECTOR X-369 - REACTIVITY SW LAMP WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 884 (Y/B) 2

886 (B)

X-369REACTIVITY SW LAMP SP-058 X-369REACTIVITY SW LAMP SP-022

84131048

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Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 37 CONNECTOR X-370 - Main Harness/Engine Power Connection CONNECTOR X-370 - Main Harness/Engine Power Connection PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 25 (R) X-007CAB Power Fuse X-370Power Wire harnesses - Electrical schematic frame 02 (55.100) 686 (R) PDU-module split X-370Main Harness/Engine Power Connection SP-036

84806654

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Electrical systems - Harnesses and connectors

CONNECTOR X-371 - Power off 2 PIN WIRE NUMBER NUMBER 1 1182 (W)

CONNECTOR X-371 - Power off 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-011 X-371Power off 2

82944111

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Wire harnesses - Electrical schematic frame 15 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-374 - 4WD SW PIN WIRE NUMBER NUMBER 1 773 (TQ) 2 251 (S/U)

CONNECTOR X-374 - 4WD SW CIRCUIT REFERENCE X-3744WD SW X-230XCM CN3-A X-3744WD SW SP-020

87745322

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-375 - Diff.Lock SW PIN NUMBER 1 2 3 4 5 6 7

255 252 259 254 276 256 261

WIRE NUMBER

CONNECTOR X-375 - Diff.Lock SW CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

(R/Y) (S/U) (S/U) (R/Y) (R/G) (S/U) (R/G)

X-375Diff.Lock SW SP-017 SP-020 X-375Diff.Lock SW SP-020 X-375Diff.Lock SW X-375Diff.Lock SW SP-017 X-375Diff.Lock SW SP-026 SP-020 X-375Diff.Lock SW X-375Diff.Lock SW SP-026

87745329

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-376 - Diagnostic Socket PIN NUMBER A B C D E

WIRE NUMBER 841 855 824 825 148

F G

027 (W/U)

H J

(B) (O/W) (Y) (G) (N/W)

CONNECTOR X-376 - Diagnostic Socket CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-376Diagnostic Socket SP-022 SP-030 X-376Diagnostic Socket SP-085 X-376Diagnostic Socket SP-084 X-376Diagnostic Socket X-376Diagnostic Socket X-001Main Harness/ Engine Connection X-450ADIC CN1 X-376Diagnostic Socket -

87516075

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Wire harnesses - Electrical schematic frame 11 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-377 - ADIC CN3 PIN WIRE NUMBER NUMBER 1 154 (N/R) 2

791 (N/B)

792 (N/L)

807 (S/U)

5 6

CONNECTOR X-377 - ADIC CN3 CIRCUIT REFERENCE X-378ISO 11786 X-377ADIC CN3 X-378ISO 11786 X-377ADIC CN3 X-378ISO 11786 X-377ADIC CN3 X-378ISO 11786 X-377ADIC CN3 -

SOCKET SOCKET SOCKET SOCKET

87710588

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-378 - ISO 11786 SOCKET CONNECTOR X-378 - ISO 11786 SOCKET WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 791 (N/B) 2

792 (N/L)

154 (N/R)

807 (S/U)

5 6 7

796 (U) 793 (B)

X-378ISO 11786 SOCKET X-377ADIC CN3 X-378ISO 11786 SOCKET X-377ADIC CN3 X-378ISO 11786 SOCKET X-377ADIC CN3 X-378ISO 11786 SOCKET X-377ADIC CN3 X-378ISO 11786 SOCKET SP-029 X-378ISO 11786 SOCKET SP-022

87357892

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Wire harnesses - Electrical schematic frame 16 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 38 CONNECTOR X-380 - Front Loader Disposition — CAB-Mid mount-Front loader split CONNECTOR X-380 - Front Loader Disposition — CAB-Mid mount-Front loader split PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 X-380Front Loader Disposition Wire harnesses - Electrical 905 (U) SP-108 schematic frame 22 (55.100) 906 (U) X-380CAB-Mid mount-Front loader split X-395Front_loader ready 7 POLES SOCKET 2 282 (G) X-392FRONT LOADER READY 867 (G) X-380Front Loader Disposition X-380CAB-Mid mount-Front loader split X-395Front_loader ready 7 POLES SOCKET 3 X-380Front Loader Disposition 896 (R) X-392FRONT LOADER READY 897 (R) X-380CAB-Mid mount-Front loader split X-395Front_loader ready 7 POLES SOCKET 4 X-120Modulo Relays R9-R16 + 713 (S) Fuses F37-F40 X-380Front Loader 901 (S) Disposition X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader split 5 899 (Y) X-394STOLL COMFORT DRIVE 900 (Y) SWITCH X-380Front Loader Disposition X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader split 6 898 (N) X-393STOLL TOOL LOCKING 902 (N) SWITCH X-380Front Loader Disposition X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader split

87710588

Front Loader Disposition

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Electrical systems - Harnesses and connectors

87691968

CAB-Mid mount-Front loader split

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Electrical systems - Harnesses and connectors

CONNECTOR X-381 - Main/ Trailer Brake Connection — Trailer Brake/CAB split CONNECTOR X-381 - Main/ Trailer Brake Connection — Trailer Brake/CAB split WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 302 (B) 879 (B)

273 (W) 296 (W)

846 (Y/U) 880 (Y/U)

925 (N/S) 928 (N/S)

926 (N/W) 927 (N/W)

SP-022 X-381Main/ Trailer Brake Connection X-359Trailer brake LAMP switch X-381Trailer Brake-CAB split X-399Trailer brake LAMP switch (2° connector) X-381Trailer Brake-CAB split X-460ADIC CN2 X-381Main/ Trailer Brake Connection X-381Main/ Trailer Brake Connection SP-111 X-381Trailer Brake-CAB split SP-112 SP-113 X-381Main/ Trailer Brake Connection X-502Trailer Brake Safety switch 2 X-381Trailer Brake-CAB split X-503Trailer Brake Safety switch 1 X-381Trailer Brake-CAB split X-140Modulo Relays R17-R24 + Fuses F41-F44 X-381Main/ Trailer Brake Connection

87688719

Main/ Trailer Brake Connection

87691924

Trailer Brake/CAB split

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Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 23 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-383 - Safety switch A pin 1 CONNECTOR X-383 - Safety switch A pin 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 101 (O/B)

X-300MAIN Connection X-383Safety Wire harnesses - Electrical schematic frame 13 (55.100) switch A pin 1

87581782

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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

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Wire harnesses - Electrical schematic frame 23 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-385 - Main Circuit Connection 2 — Cab/Main harness connection CONNECTOR X-385 - Main Circuit Connection 2 — Cab/Main Harness Connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 559 (TQ/B) 560 (TQ/B)

624 (U) 625 (U)

706 (Y/B) 873 (Y/B)

37 (S/U) 845 (S/U)

40 (R) 789 (U)

1258 (W/R) 162 (W/R)

1232 (W/U) 1259 (W/U)

1501 (Y) 806 (Y)

1261 (L/B) 715 (L/B)

1221 (G) 1222 (G)

SP-050 X-385Cab/ Main Harness Connection X-021LH Front Lamp X-385Main Circuit Connection 2 X-075Front Wiper Motor Openable X-385Main Circuit Connection 2 SP-056 X-385Cab/ Main Harness Connection SP-058 X-385Cab/ Main Harness Connection X-385Main Circuit Connection 2 SP-042 X-197BDS SW X-385Main Circuit Connection 2 X-460ADIC CN2 X-385Cab/ Main Harness Connection SP-075 X-385Main Circuit Connection 2 SP-074 X-385Cab/ Main Harness Connection X-110Modulo Relays R1-R8 + Fuses F33-F36 X-385Cab/ Main Harness Connection X-385Main Circuit Connection 2 SP-053 X-034Lights SW X-385Main Circuit Connection 2 X-091Light Control SW X-385Cab/ Main Harness Connection SP-150 X-385Cab/ Main Harness Connection X-197BDS SW X-385Main Circuit Connection 2 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-385Cab/ Main Harness Connection SP-079 X-385Main Circuit Connection 2 SP-019 X-385Cab/ Main Harness Connection X-075Front Wiper Motor Openable X-385Main Circuit Connection 2

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Electrical systems - Harnesses and connectors

CONNECTOR X-385 - Main Circuit Connection 2 â&#x20AC;&#x201D; Cab/Main Harness Connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 559 (TQ/B) 9 (TQ/B)

624 (U) 625 (U)

706 (Y/B) 873 (Y/B)

37 (S/U) 845 (S/U)

40 (R) 789 (U)

1258 (W/R) 162 (W/R)

1232 (W/U) 1259 (W/U)

1501 (Y) 806 (Y)

1261 (L/B) 715 (L/B)

1221 (G) 1222 (G)

SP-050 X-385Cab/ Main Harness Connection X-385Main Circuit Connection 2 SP-097 X-075Front Wiper Motor Openable X-385Main Circuit Connection 2 SP-056 X-385Cab/ Main Harness Connection SP-058 X-385Cab/ Main Harness Connection X-385Main Circuit Connection 2 SP-042 X-197BDS SW X-385Main Circuit Connection 2 X-460ADIC CN2 X-385Cab/ Main Harness Connection SP-075 X-385Main Circuit Connection 2 X-008BDS (Control) SP-004 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-385Cab/ Main Harness Connection X-385Main Circuit Connection 2 SP-053 X-034Lights SW X-385Main Circuit Connection 2 X-091Light Control SW X-385Cab/ Main Harness Connection X-385Cab/ Main Harness Connection SP-150 X-197BDS SW X-385Main Circuit Connection 2 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-385Cab/ Main Harness Connection SP-079 X-385Main Circuit Connection 2 SP-019 X-385Cab/ Main Harness Connection X-075Front Wiper Motor Openable X-385Main Circuit Connection 2

87736504

Main Circuit Connection 2

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Electrical systems - Harnesses and connectors

87736477

Cab/ Main Harness Connection

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Electrical systems - Harnesses and connectors

CONNECTOR X-386 - LH Rear SMV PIN WIRE NUMBER NUMBER 1 1301 (TQ/B) 2 379 (B)

CONNECTOR X-386 - LH Rear SMV CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-386LH Rear SMV SP-097 X-403Roof Ground 2 X-386LH Rear SMV

87691973

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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 (TQ) 2 304 (B)

CONNECTOR X-387 - RH Rear SMV CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical X-387RH Rear SMV SP-098 X-403Roof Ground 2 X-387RH Rear schematic frame 07 (55.100) SMV

87691973

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Electrical systems - Harnesses and connectors

CONNECTOR X-388 - PTO SOFT START LAMP CONNECTOR X-388 - PTO SOFT START LAMP WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 230 (Y/B) 2

229 (B)

X-388PTO SOFT START LAMP SP-058 X-388PTO SOFT START LAMP SP-022

84131048

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Wire harnesses - Electrical schematic frame 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-389 - Reverse Alarm PIN WIRE NUMBER NUMBER 1 1262 (U/Y) 2

1107 (B)

1350 (Y)

CONNECTOR X-389 - Reverse Alarm CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-120Modulo Relays R9-R16 + Fuses F37-F40 X-389Reverse Alarm X-400Fuse Box Ground 1 X-389Reverse Alarm X-389Reverse Alarm SP-012

84062580

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Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 14 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 39 CONNECTOR X-392 - FRONT LOADER READY CONNECTOR X-392 - FRONT LOADER READY PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 X-392Front loader ready Wire harnesses - Electrical 903 (R/G) predisposition JUMPER X-295Diode schematic frame 22 (55.100) 907 (U) X-392FRONT LOADER READY SP-108 2 282 (G) X-392FRONT LOADER READY 904 (G) X-380Front Loader Disposition X-392Front loader ready predisposition JUMPER SA1 3 X-380Front Loader Disposition 896 (R) X-392FRONT LOADER READY 4 X-120Modulo Relays R9-R16 + 711 (G/W) Fuses F37-F40 X-392FRONT 909 (G) LOADER READY X-392Front loader ready predisposition JUMPER SA1

87687242

Front loader ready

87680652

Front loader ready predisposition JUMPER

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Electrical systems - Harnesses and connectors

CONNECTOR X-393 - STOLL TOOL LOCKING SWITCH CONNECTOR X-393 - STOLL TOOL LOCKING SWITCH WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1116 (O/W) 2

898 (N)

910 (B)

SP-073 X-393STOLL TOOL LOCKING SWITCH X-393STOLL TOOL LOCKING SWITCH X-380Front Loader Disposition X-393STOLL TOOL LOCKING SWITCH SP-022

87691928

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Wire harnesses - Electrical schematic frame 22 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-394 - STOLL COMFORT DRIVE SWITCH CONNECTOR X-394 - STOLL COMFORT DRIVE SWITCH WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 1115 (O/W) 2

899 (Y)

911 (B)

SP-073 X-394STOLL COMFORT DRIVE SWITCH X-394STOLL COMFORT DRIVE SWITCH X-380Front Loader Disposition X-394STOLL COMFORT DRIVE SWITCH SP-022

87680689

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Wire harnesses - Electrical schematic frame 22 (55.100)

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 (U)

867 (G)

897 (R)

901 (S)

900 (Y)

902 (N)

X-380CAB-Mid mount-Front loader split X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader split X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader split X-395Front_loader ready 7 POLES SOCKET X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader split X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader split X-395Front_loader ready 7 POLES SOCKET X-380CAB-Mid mount-Front loader split

84185564

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Wire harnesses - Electrical schematic frame 22 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-399 - Trailer brake LAMP switch (2° connector) CONNECTOR X-399 - Trailer brake LAMP switch (2° connector) WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 273 (W)

X-399Trailer brake LAMP switch (2° connector) X-381Trailer Brake-CAB split

82944111

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Wire harnesses - Electrical schematic frame 16 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 40 CONNECTOR X-400 - Fuse Box Ground 1 PIN WIRE NUMBER NUMBER 1 186 (B) 3 639 (B) 4

636 (B)

453 (B)

449 (B)

727 (B)

550 (B)

181 (B)

521 (B)

569 (B)

1107 (B)

646 (B)

647 (B)

726 (B)

283 (B)

1218 (B)

CONNECTOR X-400 - Fuse Box Ground 1 CIRCUIT REFERENCE 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-029Electrical Seat X-400Fuse Box Ground 1 X-023LH Rear Lamp X-400Fuse Box Ground 1 X-090Flasher X-400Fuse Box Ground 1 X-024RH Rear Lamp X-400Fuse Box Ground 1 X-098Main/ 7 Pole Socket Extension X-400Fuse Box Ground 1 X-400Fuse Box Ground 1 X-389Reverse Alarm X-079 25A Socket 2 X-400Fuse Box Ground 1 X-027Cigar Lighter Base X-400Fuse Box Ground 1 X-0268A Socket X-400Fuse Box Ground 1 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-400Fuse Box Ground 1 X-048WIPER MOTOR TIMER X-400Fuse Box Ground 1

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PANEL WIRING DIAGRAM

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 14 (55.100) Wire harnesses - Electrical schematic frame 19 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-400 - Fuse Box Ground 1 WIRE NUMBER CIRCUIT REFERENCE

PIN NUMBER 1 186 (B) 3 639 (B) 4

636 (B)

453 (B)

449 (B)

727 (B)

550 (B)

181 (B)

521 (B)

569 (B)

1107 (B)

646 (B)

647 (B)

726 (B)

283 (B)

1218 (B)

740 (B)

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-029Electrical Seat X-400Fuse Box Ground 1 X-023LH Rear Lamp X-400Fuse Box Ground 1 X-090Flasher X-400Fuse Box Ground 1 X-024RH Rear Lamp X-400Fuse Box Ground 1 X-098Main/ 7 Pole Socket Extension X-400Fuse Box Ground 1 X-400Fuse Box Ground 1 X-389Reverse Alarm X-079 25A Socket 2 X-400Fuse Box Ground 1 X-027Cigar Lighter Base X-400Fuse Box Ground 1 X-0268A Socket X-400Fuse Box Ground 1 X-110Modulo Relays R1-R8 + Fuses F33-F36 X-400Fuse Box Ground 1 X-048WIPER MOTOR TIMER X-400Fuse Box Ground 1 X-092Hazard SW X-400Fuse Box Ground 1

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PANEL WIRING DIAGRAM

Electrical systems - Harnesses and connectors

CONNECTOR X-401 - 40A SOCKET GROUND CONNECTOR X-401 - 40A SOCKET GROUND WIRE NUMBER CIRCUIT REFERENCE PANEL WIRING DIAGRAM

PIN NUMBER 1 378 (B) 2

1260 (B)

1266 (B)

X-401 40A SOCKET ISO GROUND X-402 40A SOCKET 2 X-300Trasmission/ Main Harness Connection X-401 40A SOCKET GROUND X-40140A SOCKET GROUND X-087 3Â° Distributor Solenoid

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Wire harnesses - Electrical schematic frame 04 (55.100) Wire harnesses - Electrical schematic frame 09 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100) Wire harnesses - Electrical schematic frame 10 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-402 - 40A SOCKET 2 PIN WIRE NUMBER NUMBER 1 378 (B)

CONNECTOR X-402 - 40A SOCKET 2 CIRCUIT REFERENCE X-40140A SOCKET ISO GROUND X-40240A SOCKET 2

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PANEL WIRING DIAGRAM

Wire harnesses - Electrical schematic frame 09 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-403 - Roof Ground 2 CONNECTOR X-403 - Roof Ground 2 CIRCUIT REFERENCE

PIN WIRE NUMBER NUMBER 1 39 (B) X-198BDS SW Lamp X-403Roof Ground 2 3 604 (B) X-403Roof Ground 2 X-037Rear Wiper and Washer SW Lamp 4 599 (B) X-075Front Wiper Motor Openable X-403Roof Ground 2 5 596 (B) X-038Rear Wiper X-403Roof Ground 2 6 509 (B) X-022RH Front lamp X-403Roof Ground 2 7 520 (B) X-021LH Front Lamp X-403Roof Ground 2 9 511 (B) X-403Roof Ground 2 X-059RH Grab Rail Work Lamp 10 510 (B) X-403Roof Ground 2 X-060LH Grab Rail Work Lamp 11 499 (B) X-403Roof Ground 2 X-054Spot Lamp 12 477 (B) X-058LH Front Roof Lamp X-403Roof Ground 2 13 476 (B) X-056LH Rear Work Lamp X-403Roof Ground 2 14 474 (B) X-057RH Front Roof Lamp X-403Roof Ground 2 15 601 (B) X-403Roof Ground 2 X-071RH Rotating Beacon Lead/Socket 16 438 (B) X-150Fuse &amp; Relay Module X-403Roof Ground 2 17 494 (B) X-062Change Over SW Lamp X-403Roof Ground 2 18 451 (B) X-031A/C SW X-403Roof Ground 2 19 455 (B) X-403Roof Ground 2 X-040A/C SW LED 20 473 (B) X-052Roof Lamp 2 X-403Roof Ground 2 21 475 (B) X-403Roof Ground 2 X-055RH Rear Work Lamp 22 606 (B) X-403Roof Ground 2 X-033Rotating Beacon SW Lamp 23 611 (B) X-403Roof Ground 2 X-073LH Rotating Beacon Lead/Socket 24 644 (B) X-039Radio X-403Roof Ground 2 25 665 (B) X-150Fuse &amp; Relay Module X-403Roof Ground 2 26 666 (B) X-150Fuse &amp; Relay Module X-403Roof Ground 2 27 667 (B) X-403Roof Ground 2 X-150Fuse &amp; Relay Module 28 762 (B) X-096LH License Plate Lamp X-403Roof Ground 2 29 763 (B) X-097RH License Plate Lamp X-403Roof Ground 2 30 1238 (B) X-035Lights SW Lamp X-403Roof Ground 2

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PANEL WIRING DIAGRAM Wire harnesses - Electrical schematic frame 01 (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 20 (55.100) Wire harnesses - Electrical schematic frame 21 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-403 - Roof Ground 2 CIRCUIT REFERENCE

PIN WIRE NUMBER NUMBER 1 39 (B) X-198BDS SW Lamp X-403Roof Ground 2 3 604 (B) X-403Roof Ground 2 X-037Rear Wiper and Washer SW Lamp 4 599 (B) X-075Front Wiper Motor Openable X-403Roof Ground 2 5 596 (B) X-038Rear Wiper X-403Roof Ground 2 6 509 (B) X-022RH Front lamp X-403Roof Ground 2 7 520 (B) X-021LH Front Lamp X-403Roof Ground 2 11 499 (B) X-403Roof Ground 2 X-054Spot Lamp 12 477 (B) X-058LH Front Roof Lamp X-403Roof Ground 2 13 476 (B) X-056LH Rear Work Lamp X-403Roof Ground 2 14 474 (B) X-057RH Front Roof Lamp X-403Roof Ground 2 15 601 (B) X-403Roof Ground 2 X-071RH Rotating Beacon Lead/Socket 16 438 (B) X-150Fuse &amp; Relay Module X-403Roof Ground 2 18 451 (B) X-031A/C SW X-403Roof Ground 2 19 455 (B) X-403Roof Ground 2 X-040A/C SW LED 20 473 (B) X-052Roof Lamp 2 X-403Roof Ground 2 21 475 (B) X-403Roof Ground 2 X-055RH Rear Work Lamp 22 606 (B) X-403Roof Ground 2 X-033Rotating Beacon SW Lamp 23 611 (B) X-403Roof Ground 2 X-073LH Rotating Beacon Lead/Socket 24 644 (B) X-039Radio X-403Roof Ground 2 25 665 (B) X-150Fuse &amp; Relay Module X-403Roof Ground 2 26 666 (B) X-150Fuse &amp; Relay Module X-403Roof Ground 2 27 667 (B) X-403Roof Ground 2 X-150Fuse &amp; Relay Module 30 1238 (B) X-035Lights SW Lamp X-403Roof Ground 2 31 379 (B) X-403Roof Ground 2 X-386LH Rear Slow Moving Vehicle Sign 32 304 (B) X-403Roof Ground 2 X-387RH Rear Slow Moving Vehicle Sign

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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 1 234 (B) X-250Home-Enter SW X-410Steering Wire harnesses - Electrical schematic frame 05 (55.100) Column Ground 2 235 (B) X-250Home-Enter SW X-410Steering Wire harnesses - Electrical schematic frame 07 (55.100) Column Ground Wire harnesses - Electrical 3 626 (B) X-410Steering Column Ground schematic frame 07 (55.100) X-074Front Wiper Motor Fixed Wire harnesses - Electrical 4 522 (B) X-001Main Harness/ Engine schematic frame 08 (55.100) Connection X-410Steering Column Wire harnesses - Electrical Ground schematic frame 09 (55.100) 5 294 (B) X-460ADIC CN2 X-410Steering Wire harnesses - Electrical Column Ground schematic frame 15 (55.100) 6 238 (B) X-270Home-Enter SW Lamp Wire harnesses - Electrical X-410Steering Column Ground schematic frame 16 (55.100) 7 236 (B) X-260UP-Down SW X-410Steering Wire harnesses - Electrical Column Ground schematic frame 16 (55.100) 8 237 (B) X-260UP-Down SW X-410Steering Column Ground 9 239 (B) X-290UP-Down SW Lamp X-410Steering Column Ground 10 648 (B) X-410Steering Column Ground X-028Cigar Lighter OPT Base 11 443 (B) X-044Thermostat No Frost A/C X-410Steering Column Ground 12 457 (B) X-045A/C CN X-410Steering Column Ground

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 42 CONNECTOR X-420 - Engine ground PIN WIRE NUMBER NUMBER 1 44 (B) 2

1 (B)

313 (B)

335 (B)

311 (B)

312 (B)

1174 (B)

576 (B)

1247 (B)

PIN WIRE NUMBER NUMBER 1 44 (B) 2 1 (B) 3 313 (B) 4

335 (B)

311 (B)

312 (B)

1174 (B)

576 (B)

1247 (B)

CONNECTOR X-420 - Engine ground CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-001Main Harness/ Engine Connection X-460ADIC CN2 X-892Battery Negative Stud X-893Boost Terminal Negative X-420Engine ground X-937EDC17 CONNECTOR 2 X-950Water in fuel X-420Engine ground X-420Engine ground X-937EDC17 CONNECTOR 2 X-420Engine ground X-937EDC17 CONNECTOR 2 X-357Engine Intake Air Filter X-420Engine ground X-088A/C compressor X-420Engine ground X-362FUEL HEATER X-420Engine ground

Wire harnesses - Electrical schematic frame 01 (55.100) Wire harnesses - Electrical schematic frame 05 (55.100) Wire harnesses - Electrical schematic frame 17 (55.100)

CONNECTOR X-420 - Engine ground CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-004 X-420Engine ground X-420Engine ground X-002PDU split X-420Engine ground X-937EDC17 CONNECTOR 2 X-950Water in fuel X-420Engine ground X-420Engine ground X-937EDC17 CONNECTOR 2 X-420Engine ground X-937EDC17 CONNECTOR 2 X-357Engine Intake Air Filter X-420Engine ground X-088A/C compressor X-420Engine ground X-362FUEL HEATER X-420Engine ground

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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 17 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 45 CONNECTOR X-450 - ADIC CN1 PIN WIRE NUMBER NUMBER 1 263 (G) 2 303 (N) 3 4 5

815 (Y) 814 (G) 34 (W/B)

6 7

265 (B) 225 (W)

8 9

226 (R) 270 (S)

10 11 12 13 14 15

231 (B) 295 (U)

16 17 18 19 20

170 (O/B) 171 (O/W) 240 (K/B)

241 (W/B)

22 23 24 25

242 (N/B) 243 (U/B) 027 (W/U)

275 (TQ/W)

CONNECTOR X-450 - ADIC CN1 CIRCUIT REFERENCE X-450ADIC CN1 X-355Seat SW X-450ADIC CN1 X-300Trasmission/ Main Harness Connection X-450ADIC CN1 SP-083 X-450ADIC CN1 SP-082 X-321Foot Pedal Sensor SW X-450ADIC CN1 SP-028 X-450ADIC CN1 X-321Foot Pedal Sensor SW X-450ADIC CN1 X-324Hand Throttle X-450ADIC CN1 X-356Brakes not latched SW X-450ADIC CN1 X-324Hand Throttle X-450ADIC CN1 X-450ADIC CN1 X-300Trasmission/ Main Harness Connection 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 X-001Main Harness/ Engine Connection X-450ADIC CN1

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100)

Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 1 263 (G) 2 303 (N) 3 4 5

815 (Y) 814 (G) 34 (W/B)

6 7

265 (B) 225 (W)

8 9 10 11 12 13 14 15

226 (R) 231 (B) 295 (U)

16 17 18 19 20

240 (K/B)

241 (W/B)

22 23 24 25

242 (N/B) 243 (U/B) 027 (W/U)

275 (TQ/W)

CONNECTOR X-450 - ADIC CN1 CIRCUIT REFERENCE X-450ADIC CN1 X-355Seat SW X-450ADIC CN1 X-300Trasmission/ Main Harness Connection SP-083 X-450ADIC CN1 SP-082 X-450ADIC CN1 X-321Foot Pedal Sensor SW X-450ADIC CN1 SP-028 X-450ADIC CN1 X-321Foot Pedal Sensor SW X-450ADIC CN1 X-324Hand Throttle X-450ADIC CN1 X-324Hand Throttle X-450ADIC CN1 X-450ADIC CN1 X-300Trasmission/ Main Harness Connection 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 X-001Main Harness/ Engine Connection X-450ADIC CN1

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ELECTRICAL SCHEMATIC FRAME 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 46 CONNECTOR X-460 - ADIC CN2 PIN WIRE NUMBER NUMBER 1 11 (TQ) 2

845 (S/U)

292 (Y)

4 5 6 7 8

573 (G) 849 (R)

9 10 11 12

284 (TQ/B) 285 (TQ) 296 (W)

44 (R/G)

14 15

228 (TQ) 294 (B)

139 (R)

17 18

26 (U/Y) 290 (R)

19 20 21 22 23

288 293 291 485

24 25 26

(Y) (R) (O/U) (G/W)

CONNECTOR X-460 - ADIC CN2 CIRCUIT REFERENCE X-460ADIC CN2 X-321Foot Pedal Sensor SW X-460ADIC CN2 X-385Cab/ Main Harness Connection X-460ADIC CN2 X-001Main Harness/ Engine Connection SP-100 X-460ADIC CN2 X-358Handbrake SW X-460ADIC CN2 X-460ADIC CN2 SP-050 X-460ADIC CN2 SP-051 X-460ADIC CN2 X-381Main/ Trailer Brake Connection X-001Main Harness/ Engine Connection X-460ADIC CN2 X-324Hand Throttle X-460ADIC CN2 X-460ADIC CN2 X-410Steering Column Ground X-300Trasmission/ Main Harness Connection X-460ADIC CN2 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 X-050Cab/ Main Harness Connection -

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 15 (55.100) Wire harnesses - Electrical schematic frame 16 (55.100)

Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 1 11 (TQ) 2

845 (S/U)

292 (Y)

4 5 6 7 8

573 (G) 849 (R)

9 10 11 12 13 14 15

284 (TQ/B) 285 (TQ) 44 (R/G) 228 (TQ) 294 (B)

139 (R)

17 18

26 (U/Y) 290 (R)

19 20 21 22 23

288 293 291 485

24 25 26

(Y) (R) (O/U) (G/W)

CONNECTOR X-460 - ADIC CN2 CIRCUIT REFERENCE X-460ADIC CN2 X-321Foot Pedal Sensor SW X-460ADIC CN2 X-385Cab/ Main Harness Connection X-460ADIC CN2 X-001Main Harness/ Engine Connection SP-062 X-460ADIC CN2 X-358Handbrake SW X-460ADIC CN2 X-460ADIC CN2 SP-050 X-460ADIC CN2 SP-051 SP-004 X-420Engine ground X-324Hand Throttle X-460ADIC CN2 X-460ADIC CN2 X-410Steering Column Ground X-300Trasmission/ Main Harness Connection X-460ADIC CN2 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 X-050Cab/ Main Harness Connection -

82016219

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ELECTRICAL SCHEMATIC FRAME 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 50 CONNECTOR X-500 - Battery PIN WIRE NUMBER NUMBER 1 106 (U) 2B (B)

CONNECTOR X-500 - Battery CIRCUIT REFERENCE X-552Fuse KAM X-500Battery X-500+ Battery X-009BDS

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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 CONNECTOR X-501 - 40A SOCKET ISO 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 921 (U) 2

1250 (Y)

X-50140A SOCKET ISO 1 X-130Modulo Fuses F1-F32 X-50140A SOCKET ISO 1 X-130Modulo Fuses F1-F32

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Wire harnesses - Electrical schematic frame 09 (55.100)

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)

X-502Trailer Brake Safety switch 2 X-381Trailer Brake-CAB split

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Wire harnesses - Electrical schematic frame 23 (55.100)

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)

X-503Trailer Brake Safety switch 1 X-381Trailer Brake-CAB split

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Wire harnesses - Electrical schematic frame 23 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-504 - Safety switch B pin 1 CONNECTOR X-504 - Safety switch B pin 1 WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 104 (W)

SP-011 X-504Safety switch B pin 1

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-509 - Key Switch 30 PIN WIRE NUMBER NUMBER 1 684 (U)

CONNECTOR X-509 - Key Switch 30 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-036 X-509Key Switch 30

87747155

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Wire harnesses - Electrical schematic frame 02 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 51 CONNECTOR X-510 - Key Switch 15 PIN WIRE NUMBER NUMBER 1 690 (N)

CONNECTOR X-510 - Key Switch 15 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-510Key Switch 15 SP-070

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Wire harnesses - Electrical schematic frame 02 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-511 - Key Switch 15B PIN WIRE NUMBER NUMBER 1 691 (N)

CONNECTOR X-511 - Key Switch 15B CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-511Key Switch 15B SP-070

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Wire harnesses - Electrical schematic frame 02 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-512 - Key Switch 50 PIN WIRE NUMBER NUMBER 1 679 (S)

CONNECTOR X-512 - Key Switch 50 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-512Key Switch 50 X-130Modulo Fuses F1-F32

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Wire harnesses - Electrical schematic frame 02 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 52 CONNECTOR X-522 - Safety switch B pin 2 PIN WIRE NUMBER NUMBER 1 102 (O/W)

CONNECTOR X-522 - Safety switch B pin 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-300MAIN Connection X-522Safety Wire harnesses - Electrical schematic frame 13 (55.100) switch B pin 2

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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 (R/B) SP-001 X-533ENGINE MAXI-RELAY Wire harnesses - Electrical schematic frame 01 (55.100) MODULE R1_85 26 (B) SP-008 X-460ADIC CN2 R1_86 25 (U/Y) X-007CAB Power Fuse X-370Power PDU-module split R1_87 840 (R/Y) X-002PDU split X-533ENGINE MAXI-RELAY MODULE R2_30 277 (R) SP-001 X-533ENGINE MAXI-RELAY MODULE R2_85 18 (B/W) X-533ENGINE MAXI-RELAY MODULE X-002PDU split R2_86 13 (R/B) SP-001 X-533ENGINE MAXI-RELAY MODULE R2_87 14 (R) X-533ENGINE MAXI-RELAY MODULE SP-002

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Electrical systems - Harnesses and connectors

CONNECTOR X-534 - EDC LED PANEL PIN WIRE NUMBER NUMBER 1 89 (O/U) 2

90 (K/B)

92 (K/W)

91 (K)

7 8

99 (B/Y) 87 (B/Y)

CONNECTOR X-534 - EDC LED PANEL CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-534EDC LED PANEL X-220XCM CN2 X-534EDC LED PANEL X-220XCM CN2 X-534EDC LED PANEL X-220XCM CN2 X-534EDC LED PANEL X-220XCM CN2 X-534EDC LED PANEL SP-068 X-534EDC LED PANEL SP-068

87680680

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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 1500 (U/Y) 2 1502 (Y)

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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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-552 - Fuse KAM PIN WIRE NUMBER NUMBER 1 107 (U) 2

106 (U)

CONNECTOR X-552 - Fuse KAM CIRCUIT REFERENCE X-553Engine 1 connection X-552Fuse KAM X-552Fuse KAM X-500Battery

84175724

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-553 - Engine 1 connection CONNECTOR X-553 - Engine 1 connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 107 (U) 33 (U)

X-553Engine 1 connection X-552Fuse KAM X-553KAM extension connection X-001Engine - Cab split

87687239

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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 80 CONNECTOR X-806 - CLUTCH C SOLENOID PIN WIRE NUMBER NUMBER 1 456 (L) 2

461 (B/Y)

CONNECTOR X-806 - CLUTCH C SOLENOID CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-806CLUTCH C SOLENOID X-300MAIN Connection X-806CLUTCH C SOLENOID X-300MAIN Connection

87691973

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-807 - CLUTCH D SOLENOID CONNECTOR X-807 - CLUTCH D SOLENOID WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 481 (G/W) 2

479 (G/B)

X-807CLUTCH D SOLENOID X-300MAIN Connection X-807CLUTCH D SOLENOID X-300MAIN Connection

82012083

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Wire harnesses - Electrical schematic frame 13 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 89 CONNECTOR X-892 - Battery Negative Stud PIN WIRE NUMBER NUMBER 1 1 (B)

CONNECTOR X-892 - Battery Negative Stud CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-892Battery Negative Stud X-893Boost Terminal Negative

82032329

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Wire harnesses - Electrical schematic frame 01 (55.100)

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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Wire harnesses - Electrical schematic frame 01 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 93 PLUG CONNECTOR X-937 - EDC17 PLUG CONNECTOR 2 PLUG CONNECTOR X-937 - EDC17 PLUG CONNECTOR 2 CONNECCABLE POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM TOR PIN NUMBER NUMBER 1 Wire harnesses - Electrical 745 (R/B) X-937EDC17 PLUG CONNECTOR 2 schematic frame 17 (55.100) X-002PDU distribution Wire harnesses - Electrical 2 311 (B) X-420 Engine earth X-937EDC17 PLUG schematic frame 18 (55.100) CONNECTOR 2 3 744 (R/Y) X-937EDC17 PLUG CONNECTOR 2 X-002PDU distribution 4 312 (B) X-420 Engine earth X-937EDC17 PLUG CONNECTOR 2 5 4 (R/Y) X-937EDC17 PLUG CONNECTOR 2 X-002PDU distribution 6 313 (B) X-420 Engine earth X-937EDC17 PLUG CONNECTOR 2 7 314 (G) X-937EDC17 PLUG CONNECTOR 2 X-943 Oxygen sensor 8 165 (N/W) X-091 Light switch SP-050 9 10 11 12 13 14 329 (Y/B) X-937EDC17 PLUG CONNECTOR 2 X-947 Diff pressure sensor 15 16 17 18 19 327 (O) X-937EDC17 PLUG CONNECTOR 2 X-942 Intake air temp 20 328 (O/B) X-937EDC17 PLUG CONNECTOR 2 X-942 Intake air temp 21 22 334 (N/Y) X-937EDC17 PLUG CONNECTOR 2 X-949 Motor1- Motor2 bridge 23 24 339 (Y) S58 X-937EDC17 PLUG CONNECTOR 2 25 340 (G) S60 X-937EDC17 PLUG CONNECTOR 2 26 27 28 743 (B/W) X-937EDC17 PLUG CONNECTOR 2 X-002PDU distribution 29 30 347 (Y) X-950 Water in fuel X-937EDC17 PLUG CONNECTOR 2 31 32 33 34 35 36 330 (Y/N) X-937EDC17 PLUG CONNECTOR 2 X-947 Diff pressure sensor

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Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-937 - EDC17 PLUG CONNECTOR 2 CABLE POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM NUMBER

CONNECTOR PIN NUMBER 37 38 39 40 41

333 (U/R)

42 43 44 45 46 47 48 49 50 51 52

337 (Y) 338 (G) 332 (S)

53 54

341 (O)

55 56 57 58

331 (Y)

59 60 61 62 63

315 (N)

316 (O)

65 66 67 68 69 70

1249 (G)

71 72 73 74 75 76 77 78

X-937EDC17 PLUG CONNECTOR 2 X-949 Motor1- Motor2 bridge X-937EDC17 PLUG CONNECTOR 2 S58 X-937EDC17 PLUG CONNECTOR 2 S60 X-937EDC17 PLUG CONNECTOR 2 X-949 Motor1- Motor2 bridge X-937EDC17 PLUG CONNECTOR 2 SP-031 X-937EDC17 PLUG CONNECTOR 2 X-947 Diff pressure sensor X-937EDC17 PLUG CONNECTOR 2 X-943 Oxygen sensor X-937EDC17 PLUG CONNECTOR 2 X-943 Oxygen sensor X-001 Engine - cab distribution X-937EDC17 PLUG CONNECTOR 2 -

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Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-937 - EDC17 PLUG CONNECTOR 2 CABLE POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM NUMBER

CONNECTOR PIN NUMBER 79 323 (N/G) 80

324 (N/Y)

325 (B)

326 (B/W)

320 (B/W)

322 (G/W)

317 (S)

318 (Y)

87 88 89 90 91 92 93 94

X-937EDC17 PLUG CONNECTOR 2 X-946Temp outlet 1 X-937EDC17 PLUG CONNECTOR 2 X-946Temp outlet 1 X-937EDC17 PLUG CONNECTOR 2 X-949 Motor1- Motor2 bridge X-937EDC17 PLUG CONNECTOR 2 X-949 Motor1- Motor2 bridge X-937EDC17 PLUG CONNECTOR 2 X-945Temp outlet 2 X-937EDC17 PLUG CONNECTOR 2 X-945Temp outlet 2 X-937EDC17 PLUG CONNECTOR 2 X-943 Oxygen sensor X-937EDC17 PLUG CONNECTOR 2 X-943 Oxygen sensor -

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Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-937 - EDC17 PLUG CONNECTOR 2 CABLE POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM NUMBER

CONNECTOR PIN NUMBER 1 745 (R/B) 2

311 (B)

744 (R/Y)

312 (B)

4 (R/Y)

313 (B)

314 (G)

165 (N/W)

9 10 11 12 13 14

329 (Y/B)

15 16 17 18 19

327 (O)

328 (O/B)

21 22

334 (N/Y)

23 24 25 26 27 28

339 (Y) 340 (G) 743 (B/W)

29 30

347 (Y)

31 32 33 34 35 36

330 (Y/N)

37 38 39 40

X-937EDC17 PLUG CONNECTOR 2 X-002PDU distribution X-420 Engine earth X-937EDC17 PLUG CONNECTOR 2 X-937EDC17 PLUG CONNECTOR 2 X-002PDU distribution X-420 Engine earth X-937EDC17 PLUG CONNECTOR 2 X-937EDC17 PLUG CONNECTOR 2 X-002PDU distribution X-420 Engine earth X-937EDC17 PLUG CONNECTOR 2 X-937EDC17 PLUG CONNECTOR 2 X-943 Oxygen sensor X-937EDC17 PLUG CONNECTOR 2 X-001 Engine - cab distribution X-937EDC17 PLUG CONNECTOR 2 X-947 Diff pressure sensor X-937EDC17 PLUG CONNECTOR 2 X-942 Intake air temp X-937EDC17 PLUG CONNECTOR 2 X-942 Intake air temp X-937EDC17 PLUG CONNECTOR 2 X-949 Motor1- Motor2 bridge S58 X-937EDC17 PLUG CONNECTOR 2 S60 X-937EDC17 PLUG CONNECTOR 2 X-937EDC17 PLUG CONNECTOR 2 X-002PDU distribution X-950 Water in fuel X-937EDC17 PLUG CONNECTOR 2 X-937EDC17 PLUG CONNECTOR 2 X-947 Diff pressure sensor 84568014 22/03/2013

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Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-937 - EDC17 PLUG CONNECTOR 2 CABLE POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM NUMBER

CONNECTOR PIN NUMBER 41 333 (U/R) 42 43 44 45 46 47 48 49 50 51 52

337 (Y) 338 (G) 332 (S)

53 54

341 (O)

55 56 57 58

331 (Y)

59 60 61 62 63

315 (N)

316 (O)

65 66 67 68 69 70

1249 (G)

71 72 73 74 75 76 77 78

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Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-937 - EDC17 PLUG CONNECTOR 2 CABLE POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM NUMBER

CONNECTOR PIN NUMBER 79 323 (N/G) 80

324 (N/Y)

325 (B)

326 (B/W)

320 (B/W)

322 (G/W)

317 (S)

318 (Y)

87 88 89 90 91 92 93 94

87745798

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Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-938 - Preheat system PLUG CONNECTOR X-938 - Preheat system CABLE NUMBER POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

CONNECTOR PIN 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)

X-938 Preheat system X-94162 FPT Wire harnesses - Electrical Interface schematic frame 18 (55.100) X-938 Preheat system X-94162 FPT Interface X-938 Preheat system X-949 Motor1Motor2 bridge X-938 Preheat system X-006 Fuse glow plugs X-938 Preheat system SP-138 X-938 Preheat system X-94162 FPT Interface X-94162 FPT Interface X-938 Preheat system X-938 Preheat system X-949 Motor1Motor2 bridge

84356962

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Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-939 - EDC17 PLUG CONNECTOR 1 PLUG CONNECTOR X-939 - EDC17 PLUG CONNECTOR 1 CABLE NUMBER POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

CONNECTOR 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 21 22 23

401 (N/W)

402 (N/Y)

403 (O)

404 (O/B)

405 (O/TQ)

406 (O/U)

29 30

X-939EDC17 PLUG CONNECTOR X-940 Injectors X-939EDC17 PLUG CONNECTOR X-940 Injectors X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-940 Injectors X-939EDC17 PLUG CONNECTOR X-940 Injectors X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface -

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1 1

1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1

Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

PLUG CONNECTOR X-939 - EDC17 PLUG CONNECTOR 1 CABLE NUMBER POWER CIRCUIT REFERENCE ELECTRICAL CIRCUIT DIAGRAM

CONNECTOR PIN NUMBER 31 431 (W) 32

432 (W/O)

33 34

407 (O/W)

408 (TQ)

36 37

409 (TQ/G)

410 (TQ/W)

411 (R)

412 (R/B)

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)

X-939EDC17 PLUG CONNECTOR X-940 Injectors X-939EDC17 PLUG CONNECTOR X-940 Injectors X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-940 Injectors X-939EDC17 PLUG CONNECTOR X-940 Injectors X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR SP-201 X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface X-939EDC17 PLUG CONNECTOR X-94162 FPT Interface

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1 1

1 1 1 1 1

1 1

1 1 1

1 1 1 1

Wire harnesses - Electrical schematic frame 17 (55.100) Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

84130269

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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

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1 1 1 1 1 1 1 1

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-941 - 62 FPT interface PIN NUMBER

WIRE NUMBER

400 (N/G)

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)

397 (G/Y)

405 (O/TQ)

414 (R/U)

24 25

387 (B)

388 (B/Y)

CONNECTOR X-941 - 62 FPT interface CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

X-939EDC17 CONNECTOR 1 X-94162 Wire harnesses - Electrical schematic frame 18 (55.100) FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface SP-200 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-94162 FPT interface SP-201 X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-949Engine1-Engine2 bridge X-94162 FPT interface X-949Engine1-Engine2 bridge X-94162 FPT interface

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Electrical systems - Harnesses and connectors

PIN NUMBER 27

WIRE NUMBER

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 41

393 (B/Y)

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)

CONNECTOR X-941 - 62 FPT interface CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

X-939EDC17 CONNECTOR 1 X-94162 Wire harnesses - Electrical schematic frame 18 (55.100) FPT interface X-949Engine1-Engine2 bridge X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-939EDC17 CONNECTOR 1 X-94162 FPT interface X-938Preheating device X-94162 FPT interface X-938Preheating device X-94162 FPT interface X-94162 FPT interface X-938Preheating device X-938Preheating device X-94162 FPT interface -

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Electrical systems - Harnesses and connectors

84154706

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Electrical systems - Harnesses and connectors

CONNECTOR X-942 - Intake air temp PIN WIRE NUMBER NUMBER 1 327 (O) 2

328 (O/B)

CONNECTOR X-942 - Intake air temp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-937EDC17 CONNECTOR 2 X-942Intake air temp X-937EDC17 CONNECTOR 2 X-942Intake air temp

84607243

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Wire harnesses - Electrical schematic frame 17 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-943 - Lambda probe PIN WIRE NUMBER NUMBER 1 316 (O) 2

317 (S)

314 (G)

4 5

319 (G/W) 318 (Y)

315 (N)

CONNECTOR X-943 - Lambda probe CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-937EDC17 CONNECTOR X-943Lambda probe X-937EDC17 CONNECTOR X-943Lambda probe X-937EDC17 CONNECTOR X-943Lambda probe X-943Lambda probe SP-064 X-937EDC17 CONNECTOR X-943Lambda probe X-937EDC17 CONNECTOR X-943Lambda probe

84301132

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2 2 2

2 2

Wire harnesses - Electrical schematic frame 17 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-945 - Temp Exhaust 2 PIN WIRE NUMBER NUMBER 1 322 (G/W) 2

320 (B/W)

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

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Wire harnesses - Electrical schematic frame 17 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-946 - Temp exhaust 1 PIN WIRE NUMBER NUMBER 1 324 (N/Y) 2

323 (N/G)

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

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Wire harnesses - Electrical schematic frame 17 (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 (Y/B) 2

330 (Y/N)

331 (Y)

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

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Wire harnesses - Electrical schematic frame 17 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-949 - Engine1-Engine2 bridge CONNECTOR X-949 - Engine1-Engine2 bridge WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 325 (B) M 387 (B) F

326 (B/W) M 388 (B/Y) F

344 (G/W) M 385 (G/W) F

334 (N/Y) M 436 (N/Y) F

332 (S) M 678 (S) F

333 (U/R) M 769 (B) F

X-937EDC17 CONNECTOR 2 X-949Engine1-Engine2 bridge X-949Engine1-Engine2 bridge X-94162 FPT interface X-937EDC17 CONNECTOR 2 X-949Engine1-Engine2 bridge X-949Engine1-Engine2 bridge X-94162 FPT interface SP-064 X-949Engine1-Engine2 bridge X-949Engine1-Engine2 bridge X-94162 FPT interface X-937EDC17 CONNECTOR 2 X-949Engine1-Engine2 bridge X-938Preheating device X-949Engine1-Engine2 bridge X-937EDC17 CONNECTOR 2 X-949Engine1-Engine2 bridge X-938Preheating device X-949Engine1-Engine2 bridge X-937EDC17 CONNECTOR 2 X-949Engine1-Engine2 bridge SP-138 X-949Engine1-Engine2 bridge

87691968

Female

87710588

Male

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Wire harnesses - Electrical schematic frame 17 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 95 CONNECTOR X-950 - Water in fuel PIN WIRE NUMBER NUMBER 1 347 (Y) 2

335 (B)

345 (O)

CONNECTOR X-950 - Water in fuel CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-950Water in fuel X-937EDC17 CONNECTOR 2 X-950Water in fuel X-420Engine ground X-950Water in fuel SP-031

87709663

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Wire harnesses - Electrical schematic frame 17 (55.100)

Electrical systems - Harnesses and connectors

X-951 â&#x20AC;&#x201C; Injector cylinder 1 PIN NUMBER 1 2

Wire size 1.50H 1.50H

X-951_X-954OK

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 17 (55.100)

X-952 Injector cylinder 3 PIN NUMBER 1 2

Wire size 1.50H 1.50H

X-951_X-954OK

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

X-953 Injector cylinder 4 PIN NUMBER 1 2

Wire size 1.50H 1.50H

X-951_X-954OK

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

X-954 Injector cylinder 2 PIN NUMBER 1 2

Wire size 1.50H 1.50H

X-951_X-954OK

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

X-955 Glow plugs cylinder 1 PIN NUMBER 1

Wire size 2.50H

X-955_X-958OK

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

X-956 Glow plugs cylinder 2 PIN NUMBER 1

Wire size 2.50H

X-955_X-958OK

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

X-957 Glow plugs cylinder 3 PIN NUMBER 1

Wire size 2.50H

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

X-955_X-958OK

X-958 Glow plugs cylinder 4 PIN NUMBER 1

Wire size 2.50H

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

X-955_X-958OK

X-959 Oil pressure switch PIN NUMBER 1

Wire size 0.50H

X-959OK

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 96 X-960 Wastegate valve PIN NUMBER 1 2

Wire size 0.75H 0.75H

X-960OK

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

X-961 Boost pressure PIN NUMBER 1 2 3 4

Wire size 0.50H 0.50H 0.50H 0.50H

X-961OK

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

X-962 Segment speed 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 18 (55.100)

Electrical systems - Harnesses and connectors

X-962OK

X-963 Exhaust gas absolute pressure sensor (P3) PIN NUMBER 1 2 3

Wire size 0.50H 0.50H 0.50H

X-963OK

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

X-964 EGR PIN NUMBER 1 2 3 4 5 6

Wire size 0.75H 0.50H 0.50H 0.75H 0.50H

X-964OK

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

X-965 Increment speed Wire size

Cavity No. 1 2 3

0.50H 0.50H 0.50H

X-965OK

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

X966 TVA PIN NUMBER 1 2 3 4 5 6

Wire size 0.50H 0.75H 0.50H

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

0.50H 0.75H

X-966OK

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 18 (55.100)

Electrical systems - Harnesses and connectors

X-967OK

X-968 Fuel temperature sensor PIN NUMBER 1 2

Wire size 0.50H 0.50H

X-968OK

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

X-969 Coolant temperature sensor PIN NUMBER 1 2

Wire size 0.50H 0.50H

X-969OK

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ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 97 X-970 Fuel metering unit HP pump PIN NUMBER 1 2

wire size 0.75H 0.75H

X-970OK

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

X-971 T3 sensor (EPIQ) PIN NUMBER 1 2

wire size 0.50H 0.50H

X-971OK

ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 18 (55.100)

X-972 Resistor RH Fan PIN NUMBER 1 2

WIRE SIZE 2.50H 2.50H

CONNECTOR X-972 - Resistor RH Fan ELECTRICAL SCHEMATIC FRAME Wire harnesses - Electrical schematic frame 05 (55.100)

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84335034

CONNECTOR X-973 - Resistor LH Fan PIN WIRE NUMBER NUMBER 1 7 (N) 2 6 (AG)

CONNECTOR X-973 - Resistor LH Fan CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-973 X-046 X-973 SP-033

Wire harnesses - Electrical schematic frame 05 (55.100)

84335034

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Fuse and relay box - Component localisation MAXI power fuses box 1. Raise the hood (1)

WLAPL4S55C601A

WLAPL4S55C602A

WLAPL4S55C601B

2. On the left-hand side immediately before the radiator there is the box (1) for the maxi fuses and the engine relays and fuses.

NOTE: the diagram alongside is shown at the back of the cover of the power fuse compartment, the K200 and K100 relays have been added by the author.

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References, wiring diagram / back of box cover. Back of cover

Power output

A - optional

Reference to the diagram K100 K200 W-001

70 A 70 A -

F-052

7,5 A

F-053

10 A

F2X

F-051

20 A

F-054

10 A

F4 F5 F6 F7 F8

F-058 F-056 F-056 F-055

200 A 60 A 60 A

Function Ignition relay. Engine supply relay. Metal contact plate, probably in the future, can be replaced by the battery isolator module ( A-008 ) if the battery is fitted at the front of the machine. Engine fuse, receives +12 V from pin 87 of the K200 . Engine fuse, receives +12 V from pin 87 of the K200 . Engine fuse, receives +12 V from pin 87 of the K200 . Fuse KAM (control unit memory) receives +12 V from the battery, it is used if the battery isolator is not fitted. Unused it receives +12 V from the battery. Not used Not used Driving module power fuse. Engine power fuse. Engine glow plugs power fuse.

Full Optional Version (ISO) 1 2

Valves F-055 - 60 A

PROTECTED CIRCUITS Power supply +30 V glow plug module connector Power supply fuses F-001, F-003, F-004, F-008, F-013, F-014, F-015, F-018, F-030, F-056 - 200 A F-031, F-033, F-036, F-037, F-048, F-049, F-050 + position lights relays (fuses F-023, F-024, F-025 ) + cab power relays (fuses F-045, F-046, F-047 ) Power supply +30 V starting relay Power supply F-057 - 60 A +30 V engine (fuses F-051, F-052, F-053 ) 87 relay

Standard Version (NASO) Valves 1 2

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Fuse and relay box - Component localisation 1. The fuse and relay box is located under the panel (1) covering the left fender.

WLAPL4S55C603A

WLAPL4S55C604A

WLAPL4S55C605A

2. Underneath the covering there may be the fuse and relay box (1) .

KAM fuse (control unit memory), if the battery isolator is fitted under the steps. 3. Underneath the right-hand steps, under the battery cover, with the battery isolator module, there is a trailing fuse (1) that protects the memory of the control units, F-059 - 5 A KAM (control unit memory). NOTE: In the case of machines with the battery under the right-hand steps but without a battery isolator, see F3 table Fuse and relay box - Static description Fuses and relays (55.100) (References, wiring diagram / back of box cover).

ISO version LAYOUT OF FUSES AND RELAYS Version - Cab - Power shuttle - Dual Command (2 Speed Power Shift) - Creeper - Electronic rear lift EDC - Front loader setup Valves F-001 F-002 F-003 F-004 F-005 F-006 F-007 F-008

Amps 15 5 15 15 5 5 20 15

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Valves

Amps

F-009 F-010

5 5

F-011 F-012 F-013 F-014 F-015 F-016 F-017 F-018 F-019

F-020 F-021 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-043

15 5 15 15 7.5 20 5

10 10 5 7.5 5 3 15 10 20 30 40 15 10 5 10 7.5 5 7.5

PROTECTED CIRCUITS (+ 12 V 15/54 Key) - Electronic lift mouse ( EDC ) (+ 12 V 15/54 Key) - PTO rear, differential lock backlighting, 4WD engagement, reactivity switch (+ 12 V 15/54 Key) - Speed sensor and pressure switches Not used (+ 12 V F-056 - 200 A ) - Third right fan speed (+ 12 V F-056 - 200 A) - Brake lights (+ 12 V F-056 - 200 A) - Full beam headlights (+ 12 V K-001 ) - Work lights (+ 12 V 15/54 Key) - Air conditioning control unit (+ 12 V F-056 - 200 A ) - Fourth left fan speed (+ 12 V F-054 - 10 A) - Dashboard control unit ( ADIC ), hand brake switch, fault diagnosis socket (+ 12 V 15/54 Key) - Dashboard control unit ( ADIC ) Not used (+ 12 V 15/54 Key) - Emergency switch (+ 12 V K-002 ) - Socket ISO (+ 12 V K-002 ) - Position lights (+ 12 V K-002 ) - Position lights (+ 12 V 15/54 Key) - Clutch pedal switch (+ 12 V 15/54 Key) - Engine control unit (+ 12 V K-001 ) - Brake lights (+ 12 V 15/54 Key) - Pneumatic seat, reverse gear alarm (+ 12 V F-056 - 200 A ) - Fourth right fan speed (+ 12 V F-056 - 200 A) - Socket 25 A (+ 12 V F-056 - 200 A) - Socket 40 A (+ 12 V F-056 - 200 A) - Cigar lighter Not used (+ 12 V 15/54 Key) - Front windscreen wiper (+ 12 V F-056 - 200 A) - Lights switch (+ 12 V F-056 - 200 A) - Socket 8 A Not used (+ 12 V 15/54 Key) - Diverter Not used (+ 12 V 15/54 Key) - Trailer brake (+ 12 V 15/54 Key) - Third spool valve Not used

Relay 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

Guard Service switching Sidelights Cold start device (thermostarter) 3rd left fan speed 3rd right fan speed 4th left fan speed 4th right fan speed 3rd rear spool valve splitter (if fitted) Reverse gear alarm (if fitted) Dipped beam headlights Main Beam Headlights Dipped beam headlights switch Main beam headlights switch Front loader switch (if fitted) Front loader switch (if fitted) Front loader switch (if fitted) 84568014 22/03/2013

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Relay K-017 K-018

Guard Trailer brake (where applicable) Trailer brake (where applicable)

NASO version LAYOUT OF FUSES AND RELAYS Version - Cab - Power shuttle - Dual Command (2 Speed Power Shift) - Creeper - Electronic rear lift EDC - Front loader setup Valves

Amps

F-001

F-002

F-003

F-004 F-005 F-006

15 5 5

F-007 F-008

20 15

F-009

F-010

F-011

F-012 F-013

F-014 F-015

5 15

F-016 F-017

15 7.5

F-018

F-019

F-020

F-021 F-022

F-023 F-024 F-025 F-026

10 5 7.5 5

F-027

F-028

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PROTECTED CIRCUITS (+ 12 V F-056 - 200 A) - Third left fan speed (+ 12 V F-054 - 10 A) - Transmission control unit direct positive (+ 12 V F-056 - 200 A) - Dipped beam headlights (+ 12 V F-056 - 200 A) - Fuel heating (+ 12 V 15/54 Key) - Shuttle lever (+ 12 V 15/54 Key) - Transmission control unit (+ 12 V 15/54 Key) - Socket 40 A (+ 12 V F-056 - 200 A) - Flasher power supply (+ 12 V 15/54 Key) - Electronic lift mouse ( EDC ) (+ 12 V 15/54 Key) - PTO rear, differential lock backlighting, 4WD engagement, reactivity switch (+ 12 V 15/54 Key) - Speed sensor and pressure switches Not used (+ 12 V F-056 - 200 A ) - Third right fan speed (+ 12 V F-056 - 200 A) - Brake lights (+ 12 V F-056 - 200 A) - Full beam headlights (+ 12 V K-001 ) - Work lights (+ 12 V 15/54 Key) - Air conditioning control unit (+ 12 V F-056 - 200 A ) - Fourth left fan speed (+ 12 V F-054 - 10 A ) - Dashboard control unit ( ADIC ), hand brake switch, fault diagnosis socket (+ 12 V 15/54 Key) - Dashboard control unit (ADIC ) Not used (+ 12 V 15/54 Key) - Emergency switch (+ 12 V K-002 ) - Socket ISO (+ 12 V K-002 ) - Position lights (+ 12 V K-002 ) - Position lights (+ 12 V 15/54 Key) - Clutch pedal switch (+ 12 V 15/54 Key) - Engine control unit (+ 12 V K-001 ) - Brake lights

Electrical systems - Harnesses and connectors

Valves

Amps

F-029

F-030

F-031 F-032 F-033 F-034 F-035

30 40 15 10

F-036 F-037 F-038 F-039 F-040 F-041 F-042 F-043

5 10 5 7.5 Relay

K-001 K-002 K-003 K-004 K-005 K-006 K-007 K-008 K-009 K-010 K-011

PROTECTED CIRCUITS (+ 12 V 15/54 Key) - Pneumatic seat, reverse gear alarm (+ 12 V F-056 - 200 A ) - Fourth right fan speed (+ 12 V F-056 - 200 A) - Socket 25 A (+ 12 V F-056 - 200 A) - Socket 40 A (+ 12 V F-056 - 200 A) - Cigar lighter Not used (+ 12 V 15/54 Key) - Front windscreen wiper (+ 12 V F-056 - 200 A) - Lights switch (+ 12 V F-056 - 200 A ) - Socket 8 A Not used Not used Not used (+ 12 V 15/54 Key) - Trailer brake (+ 12 V 15/54 Key) - Third spool valve Not used Guard

Service switching Sidelights Cold start device (thermostarter) 3rd left fan speed 3rd right fan speed 4th left fan speed 4th right fan speed 3rd rear spool valve splitter (if fitted) Reverse gear alarm (if fitted) Dipped beam headlights Main Beam Headlights

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Fuse and relay box - Static description Fuses and relays T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

ISO version Model with: Cab - Powershuttle - Dual Command (2-stage powershift) - crawler gear - EHR rear-mounted lift EDC - Front loader setup NOTE: Note when replacing relays on the electrical system that all replacement parts are identical to the parts being replaced, and are placed in the same position. The use of relays of different sizes and function can - even if they are interchangeable - impair control over the vehicle in a dangerous manner.

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WLAPL4S55C601H

NOTE: The ID numbers used can be found on the circuit diagrams; replace the letter R on the relay with the letter K.

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WLAPL4S55C601G

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NASO version LAYOUT OF FUSES AND RELAYS Version - Cabin - Powershuttle - Dual Command (2-stage powershift transmission) - crawler gear - rear-mounted powerlift with EHR - setting of front loader -

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WLAPL4S55C602H

NOTE: The ID numbers used can be found on the circuit diagrams; replace the letter R for 'Relay' with the letter K.

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WLAPL4S55C602G

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Fuse and relay box - Component localisation Cab fuses and relays layout ATTENTION: If electrical system relays need to be changed, check that correct spare parts are used and that they are fitted in the correct positions. The use of structurally or functionally different relays - even if interchangeable could seriously compromise tractor control with dangerous results.

WLAPL4S55C603G

F-6

Valves

Diagram correspondence F-045 15

F-5

F-046

F-4

F-047

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Amps

PROTECTED CIRCUITS (+ 12 V K-026 ) - Rear window wiper (+ 12 V K-026 ) - Fan speed switch, air conditioning switch (+ 12 V K-026 ) - Radio

Electrical systems - Harnesses and connectors

Valves F-3

Diagram correspondence F-048 15

F-2

F-049

F-1

F-050

Relays R1 R2 R3 R4

Diagram correspondence K-028 K-026 K-025 K-027

Amps

PROTECTED CIRCUITS (+ 12 V F-056 - 200 A) Rotating beacon, ceiling light (+ 12 V F-056 - 200 A) Rear work lights (+ 12 V F-056 - 200 A) Front work lights

Guard Rear work lamps Canopy power supply Air conditioning compressor Front work lamps

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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 02 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Wire harnesses - Electrical schematic frame 04 POWER TAKE-OFF, 4-WHEEL DRIVE AND DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Wire harnesses - Electrical schematic frame 06 WORK LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Wire harnesses - Electrical schematic frame 06 WORK LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 T5.95 NA, T5.105 NA, T5.115 NA

Wire harnesses - Electrical schematic frame 07 LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Wire harnesses - Electrical schematic frame 07 LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 T5.95 NA, T5.105 NA, T5.115 NA

Wire harnesses - Electrical schematic frame 08 WINDSCREEN WIPER AND ROTATING BEACONS . . . . . . . . 60 Wire harnesses - Electrical schematic frame 11 CAN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Wire harnesses - Electrical schematic frame 13 TRANSMISSION CONTROL (first part) . . . . . . . . . . . . . . . . . . . . 76 Wire harnesses - Electrical schematic frame 14 TRANSMISSION CONTROL (second part) . . . . . . . . . . . . . . . . . 78 Wire harnesses - Electrical schematic frame 15 CONTROL PANEL (First part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Wire harnesses - Electrical schematic frame 16 CONTROL PANEL (Second part) . . . . . . . . . . . . . . . . . . . . . . . . . 82 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Wire harnesses - Electrical schematic frame 16 CONTROL PANEL (Second part) . . . . . . . . . . . . . . . . . . . . . . . . . 84 T5.95 NA, T5.105 NA, T5.115 NA

Wire harnesses - Electrical schematic frame 17 ENGINE (First part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Wire harnesses - Electrical schematic frame 18 ENGINE (Second part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Wire harnesses - Electrical schematic frame 19 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Wire harnesses - Electrical schematic frame 19 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 T5.95 NA, T5.105 NA, T5.115 NA

Wire harnesses - Electrical schematic frame 20 ROOF RELAYS AND FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Wire harnesses - Electrical schematic frame 21 LIGHTS AND FLASHERS CONTROL . . . . . . . . . . . . . . . . . . . . . 96 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Wire harnesses - Electrical schematic frame 21 LIGHTS AND FLASHERS CONTROL . . . . . . . . . . . . . . . . . . . . . 98 T5.95 NA, T5.105 NA, T5.115 NA

Wire harnesses - Electrical schematic frame 22 FRONT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Wire harnesses - Electrical schematic frame 23 ITALIAN MARKET TRAILER BRAKE VALVE . . . . . . . . . . . . . . 102 Fuse and relay box - Component localisation MAXI power fuses box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397 Fuse and relay box - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399 Fuse and relay box - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 Fuse and relay box - Static description Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Wire connectors - Component Diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Wire connectors - Component diagram 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Wire connectors - Component diagram 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Wire connectors - Component diagram 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Wire connectors - Component diagram 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Wire connectors - Component diagram 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Wire connectors - Component diagram 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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Wire connectors - Component diagram 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Wire connectors - Component diagram 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Wire connectors - Component diagram 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Wire connectors - Component diagram 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Wire connectors - Component diagram 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Wire connectors - Component diagram 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Wire connectors - Component diagram 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Wire connectors - Component diagram 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 Wire connectors - Component diagram 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Wire connectors - Component diagram 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 Wire connectors - Component diagram 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Wire connectors - Component diagram 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 Wire connectors - Component diagram 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 Wire connectors - Component diagram 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Wire connectors - Component diagram 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 Wire connectors - Component diagram 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Wire connectors - Component diagram 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 Wire connectors - Component diagram 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Wire connectors - Component diagram 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Wire connectors - Component diagram 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Wire connectors - Component diagram 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Wire connectors - Component diagram 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Wire connectors - Component diagram 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Wire connectors - Component diagram 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Wire connectors - Component diagram 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 Wire connectors - Component diagram 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Wire connectors - Component diagram 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 Wire connectors - Component diagram 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 Wire connectors - Component diagram 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Wire connectors - Component diagram 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 Wire connectors - Component diagram 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 Wire connectors - Component diagram 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 Wire connectors - Component diagram 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 Wire connectors - Component diagram 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 Wire connectors - Component diagram 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 Wire connectors - Component diagram 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Wire connectors - Component diagram 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 Wire connectors - Component diagram 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 Wire connectors - Component diagram 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 Wire connectors - Component diagram 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 Wire connectors - Component diagram 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 Wire connectors - Component diagram 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

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Wire connectors - Component diagram 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 Wire connectors - Component diagram 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 Wire connectors - Component diagram 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377 Wire connectors - Component diagram 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 Wire connectors - Component diagram 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391 Wire connectors - Component diagram 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395 Wire harnesses - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wire harnesses - Electrical schema ADIC CONTROL PANEL CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Wire harnesses - Electrical schema TRANSMISSION CONTROL UNIT, ELECTRONIC LIFT, 4 DRIVING WHEELS, DIFFERENTIAL LOCK, POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Wire harnesses - Electrical schematic frame 01 BATTERY, ALTERNATOR AND POWER SUPPLY UNIT (with and without battery isolator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Wire harnesses - Electrical schematic frame 03 ELECTRONIC LIFT (EDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Wire harnesses - Electrical schematic frame 05 AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Wire harnesses - Electrical schematic frame 09 AUXILIARY SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Wire harnesses - Electrical schematic frame 10 BRAKE LIGHTS, LICENSE PLATE LIGHT AND THIRD SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Wire harnesses - Electrical schematic frame 10 BRAKE LIGHTS, LICENSE PLATE LIGHT AND THIRD SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 T5.95 NA, T5.105 NA, T5.115 NA

Wire harnesses - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 Wire harnesses - Identification ELECTRICAL SYSTEMS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 T5.95 INT, T5.95 WE, T5.105 INT, T5.105 WE, T5.115 INT, T5.115 WE

Wire harnesses - Identification ELECTRICAL SYSTEMS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 T5.95 NA, T5.105 NA, T5.115 NA

Wire harnesses - Measure Digital multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 Wire harnesses - Overview HOW TO USE THE WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Wire harnesses - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 Wire harnesses - Rewire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413

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Electrical systems - 55 Engine starting system - 201

T5.105 T5.115 T5.95

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Contents Electrical systems - 55 Engine starting system - 201

FUNCTIONAL DATA Engine starter Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine starter Remove and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Electrical systems - Engine starting system

Engine starter - 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 Coupling Lever 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 starter - Remove and assembly 1.

Unscrew the motor retaining screw (1), then disconnect the battery negative cable (3) and the engine ground cable (2) .

ATTENTION: Take great care the negative cable of the battery does not come into contact with the metal parts of the chassis.

WLAPL4S55C307A

WLAPL4S55C308A

WLAPL4S55C309A

Remove the plastic screw (1) retaining the guard (2) . Then remove the guard

After taking out the bolt remove the three positive terminals (2): - power supply from battery - power supply to the engine shunt box and mega fuses - alternator charging cable.

Remove the coil cable (1) from the starting relay.

To reassemble the starter motor, carry out the removal operations in reverse order.

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Electrical systems - Engine starting system

Engine starter - Disassemble NOTE: refer to image in Engine starter - 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 the switch. 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 do not require replacement during the entire 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 starter - Assemble 1.

To reassemble the starter motor, carry out the disassembly operations ( Engine starter - Disassemble (55.201)) in reverse order.

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 starter - 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 the 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 starter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine starter - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine starter - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine starter - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine starter - Remove and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - 55 Alternator - 301

T5.105 T5.115 T5.95

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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 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Alternator Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Tension adjust belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Electrical systems - Alternator

Alternator - General specification Type

Iskra AAK4314 Grounded negative 14 V 13000 RPM 120 A 2.7 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 - Dynamic description Alternator charging circuit

SEZ55CAP4F-1

1. 2. 3. 4. 5.

Starter switch Alternator charge LED Battery Alternator electronic voltage regulation circuit Alternator

B+ Battery connector D+ Alternator charge indicator W Not used

ALTERNATOR FUNCTIONING When the starter key is turned, low current passes from the battery through the rotor field wiring. The circuit closes between the LED indicating the charge, the alternator (D+) terminal, the rotor field winding, the alternator regulator and earth (ground). At this point the LED illuminates and the rotor is partially magnetized. When the engine starts and the rotor, which is partially magnetised, rotates inside the stator windings, three-phase alternating current is generated. A constant quantity of this current is transformed into direct current by three field diodes incorporated in the rectifier unit. The direct current is then reintroduced into the circuit to increase current flow through the rotor field winding. This action causes a constant increase in the rotor magnetic field, together with a rapid increase of current and voltage output. As the generated voltage output (reflected by (D+) terminal) increases, the LED intensity decreases and when the voltage at the (D+) terminal equals that on the battery side of the warning light, the light goes out. Voltage continues to increase until it reaches the pre-stabilized regulated voltage level. If the driving belt breaks, there will be no voltage accumulation in the alternator. The charge warning light will remain on - indicating the presence of a fault.

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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 Gaskets Capacitor Rear bearing Brush holder Brushes Rubber seal 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: •

NEVER MAKE OR BREAK any charging circuit connection, including the battery, when 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 whilst 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.

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.

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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.

Raise the hood and remove the right-hand plastic guard.

WLAPL4S55C303A

WLAPL4S55C304A

WLAPL4S55C305A

WLAPL4S55C306A

Slightly loosen the alternator pivot screw ( (1) , 4 ). Loosen the screws of the tensioning bracket and the lock nut of the tie-rod, then loosen the latter completely, and remove the belt (2) .

Disconnect the charging warning light cable (1) and the battery charging cable (2) .

Unscrew the pivot screw (1) and remove the alternator.

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Electrical systems - Alternator

Alternator - Install 1.

Refit the alternator by following the removal procedure in reverse order.

NOTE: During 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 previously described.

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Index Electrical systems - 55 Alternator - 301 Alternator - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Alternator - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Alternator - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Alternator - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Alternator - Tension adjust belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Alternator - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Battery - 302

T5.105 T5.115 T5.95

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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 1x960 132 AÂˇh 6 35 kg (77.16 lb) Negative

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Electrical systems - Battery

Battery - Dynamic description DESCRIPTION AND OPERATION The 132 A·h battery is fitted on all models equipped with the cab air-conditioning system and is installed in the compartment under the right-hand steps. The four main functions of a battery are: • to supply a source of electric energy for starting, switching on and running the instruments. • controlling the electrical system. • to supply electricity when the power required is higher than that produced by the alternator. • to support inactive loads from the radio and the 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-hand steps. To access the battery, you need to proceed as follows: 1.

Move the catch (1) to the right, then lift the steps that will rotate on the pivot screws.

Use the knob (2) to take the cover off the battery compartment.

Disconnect the ground lead from the battery negative terminal and put it securely away from the chassis.

Loosen the bolt and disconnect the positive cable from the battery, making sure that it does not touch the battery.

Using the handles, fitted on both ends of the battery, lift and remove the battery from its housing. WLAPL4S55C302A

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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: •

Make sure that the battery is clean and there are no traces of electrolyte leakage, also check that the breather covers are correctly 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 Only one type of battery ( 132 AÂˇh ) is used on the range of tractors. This chapter gives the procedure for charging the 132 AÂˇh and 100 AÂˇh battery (even if, for the moment, it 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 T5.115 T5.95

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Electronic module View HH MENU ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 View HH MENU OF THE CONTROL PANEL (ZC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 H3 - Configurations and options control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 H4 - View software revision level control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 H5 - Switch operation test control switches (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 H8 - Clear stored calibration information (EEPROM) (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 H9 - Voltmeter diagnostic (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 HB - Display stored fault codes (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 View engine error codes list (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 View list of electronic lift error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 View list of transmission error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 View rear PTO error code listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 View list of fourâ&#x2C6;&#x2019;wheel drive error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 View list of differential lock error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 HC - Clear all stored fault codes (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 HF - View controller hardware information (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 View HH MENU OF THE TRANSMISSION (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 H1 - Calibration procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 H2 - View stored calibration values by the transmission (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 H3 - Configurations and options of the transmission (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 H4 - View software revision level of the control unit (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 H5 - Switch operation test - transmission control switches diagnostics (RW) . . . . . . . . . . . . . . . . . . . . . . . 53 H6 - Vehicle information view on the transmission (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 H7 - Vehicle test modes (RW transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 H8 - Clear stored calibration information (EEPROM) on the transmission control unit (RW) . . . . . . . . . . 61 H9 - Voltmeter diagnostic of the transmission control unit (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 84568014 22/03/2013

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HB - Display stored fault codes on the transmission control unit (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 HC - Clear all stored fault codes on the transmission control unit (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 HE - Display frequency inputs on the transmission control unit (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 HF - View controller hardware information transmission (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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Electrical systems - Electronic modules

Electronic modules - Fault code index Calibration U-code listing Calibration code U17 - Seat switch not activated U18 - Correct start up procedure not used U19 - Oil temperature < 10 °C, calibration is not possible U20 - Parking brake not applied U21 - ERPM is below 1250, increase throttle U22 - ERPM is above 1350, reduce throttle U23 - Shuttle lever is in neutral, shift lever to forward U24 - Incorrect range selected U25 - Main gear lever is in neutral U26 - Clutch pedal is not up, release clutch pedal U31 - Wheel speed sensed U34 - Operator present seat switch off U36 - Calibration value too high U37 - Calibration value too low CL - COLD OIL WARNING: displayed below 20 degrees C CH - HOT OIL WARNING: displayed above 100 degrees C

Description of Fault Seat switch not activated Correct start up procedure not used Oil temperature < 10 °C (50.00 °F), calibration is not possible

Parking brake not applied ERPM is below 1250, increase throttle ERPM is above 1350, reduce throttle Shuttle lever is in neutral, shift lever to forward

Incorrect range selected Main gear lever is in neutral Clutch pedal is not up, release clutch pedal Wheel speed sensed Operator present seat switch off Calibration value too high Calibration value too low COLD OIL WARNING: displayed below 20 degrees C

HOT OIL WARNING: displayed above 100 degrees 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 U18 - CORRECT START UP PROCEDURE NOT USED Possible fault modes: 1. Operator has carried out the calibration incorrectly

ERROR CODE U19 - TRANSMISSION OIL TEMPERATURE IS BELOW 10 °C (50.00 °F) Possible fault modes: 84568014 22/03/2013

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Electrical systems - Electronic modules

1. 2. 3. 4.

Transmission oil is very cold Transmission oil temperature sensor open circuit Oil temperature sensor faulty Oil temperature sensor short to ground

ERROR CODE U20 - PARKING BRAKE NOT APPLIED 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 1250, 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: 1. Operator has not selected forward on the shuttle lever 2. Open circuit between the shuttle lever and the control unit ( XCM) 3. 12 V supply to the shuttle lever is open circuit NOTE: Use the H5 switch diagnostics of the RW transmission control unit to detect if the switch is connected.

ERROR CODE U24 - INCORRECT RANGE SELECTED Possible fault modes: 1. Operator has not selected the correct range 2. The range switch ( R1 or R2) is faulty 3. The gear linkage is out of adjustment NOTE: Use the H5 switch diagnostics of the RW transmission control unit to detect if the switches ( R1 and R2) are connected.

ERROR CODE U25 - MAIN GEAR LEVER IS IN NEUTRAL Possible fault modes: 1. Operator has not selected a gear 2. The gear neutral switch is faulty 3. The gear linkage is out of adjustment NOTE: Use the H5 switch diagnostics of the RW transmission control unit to detect if the switch (G) is connected.

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Electrical systems - Electronic modules

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 U31 - WHEEL SPEED DETECTED 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 U36 - CALIBRATION VALUE TOO HIGH Possible fault modes: 1. The speed does not drop 2. No or low oil pressure to the clutch 3. Mechanical failure breaking the torque path

ERROR CODE U37 - CALIBRATION VALUE TOO LOW Possible fault modes: 1. Engine speed dropped too soon 2. Clutch pressure is not being controlled properly 3. Engine speed adjusted whilst completing calibration

ERROR CODE CL- COLD OIL WARNING: DISPLAYED BELOW 20 DEGREES C Possible fault modes: 1. Transmission oil is very cold

ERROR CODE CH- HOT OIL WARNING: DISPLAYED ABOVE 100 DEGREES C Possible fault modes: 1. Transmission oil is very hot

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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 3a).

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, 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 RW error codes and settings. 2) displaying the icons of the various levels of the programs, and for the control unit of the dashboard ZC , 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 ZC to the control unit of the transmission RW , 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.

WLAPL4S55C1005A

WLAPL4S55C1006A

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 (ZC) 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 control panel Access the HH MENU ZC 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

WLAPL4S55C1008A

WLAPL4S55C1012A

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 of the various channels 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 and the program will return to the H3 menu where it is possible to move between the various options. 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 anomalies; FACTORY = (factory settings) shows all the anomalies for the first six minutes after ignition then automatically goes into ECR mode; ECR = shows only the serious anomalies. - 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 = Switching off the tractor when one of the following conditions occurs: a) Low engine oil pressure b) High coolant temperature c) High transmission oil temperature with no motion and no operator. d) Low transmission oil temperature with no motion and no operator. YES 2 = Switching off the tractor when the YES 1 conditions occur with no operator (factory setting). NO = Switching off the tractor when not operating. - Use the UP or DOWN button ( (2) , 1) to move the arrow onto the desired choice.

WLAPL4S55C1013A

WLAPL4S55C1014A

WLAPL4S55C1009A

WLAPL4S55C1010A

- 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.

− 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 if the rear PTO speed exceeds by approximately 90 RPM that of 540 RPM and 540E RPM and 170 RPM that of 1000 RPM the warning light will not blink, basically the machine does not signal exceeding the PTO speed.

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Electrical systems - Electronic modules

- 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. Choosing the NO option displays: Battery voltage.

WLAPL4S55C1011A

WLAPL4S55C1015A

- With the ENTER buttons ( (1) , 1) you can choose from between the two options for buzzer volume management. − The display will show: YES = To enable a lower buzzer volume (factory setting). NO = To enable a higher buzzer volume. - 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 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 Gearbox in neutral Machine speed equal to 0 km/h (0.0 mph) Hand throttle and pedal throttle both in the idle speed position PTO not engaged Air-conditioning system off If these conditions are broken, 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.

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WLAPL4S55C1016A

Electrical systems - Electronic modules

Electronic module - H4 - View software revision level control panel Access the HH MENU ZC as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H4 with the UP or DOWN buttons (2), press the ENTER button (1) to access the MENU H4 program.

WLAPL4S55C1007A

WLAPL4S55C1018A

− The top portion of the display will show the identification numbers of the control unit software release in sequence: 13781 - Software type. 01 - Main release. 00 - Secondary release. 01 - Development project. 02 - 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 .

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Electrical systems - Electronic modules

Electronic module - H5 - Switch operation test control switches (control panel) Access the HH MENU ZC as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. â&#x2C6;&#x2019; Select the MENU H5 with the UP or DOWN buttons (2), press the ENTER button (1) to access the MENU H5 program.

WLAPL4S55C1007A

WLAPL4S55C1019A

WLAPL4S55C1021A

â&#x2C6;&#x2019; The top portion of the display will show the code number of the switch that has been operated.

- At the end of the test procedure the only operation that remains is to turn the key (1) onto position (A) (OFF). NOTE: Usually, in order to exit, you press the HOME button ( (1) , 1 ); this operation will not produce any result other than the display showing the code d131 . The following table lists the components to test in H5 .

d11 d60 d61 d62 d66

Code

Switch code S-019 B-013 S-015 S-007 K-11

d67 d68 d70 d71 d72 d73

S-030 S-017 A-017 A-017 S-020 S-022

Component name Handbrake Switch Accelerator pedal switch Battery cut-out switch Differential lock warning light switch High beam headlights warning light input Position lights switch Brake pedals not connected switch Left direction indicator input Right direction indicator input Brake warning light switch input Brake oil level switch 84568014 22/03/2013

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ECU pin X-460 - 8 X-450 - 7 X-460 - 2 X-450 - 15 X-460- 6 X-460 X-450 X-460 X-460 X-460 X-460

19 9 6 10 12 18

Electrical systems - Electronic modules

Code d110 d131 d132 d133 d135

Switch code S-053 S-053 S-054 S-054 S-028

Component name Home-enter switch ENTER input Home-enter switch HOME input Up-down switch UP input Up-down switch DOWN input Work lights switch

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X-450 X-450 X-450 X-450 X-460

ECU pin 20 21 23 22 23

Electrical systems - Electronic modules

Electronic module - H8 - Clear stored calibration information (EEPROM) (control panel) Access the HH MENU ZC 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

WLAPL4S55C1017A

WLAPL4S55C1020A

− 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 " EECL ". − 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

WLAPL4S55C1022A

- 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 " EECL ". 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). NOTE: The following table describes the values canceled with this option in detail. PARAMETER Implement width Maintenance Button tone Fault codes Unit of measurement Error Code Management Area Worked Odometer Dimming

Factory values 0 OFF YES No error Metric Factory 0 0 50%

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Electrical systems - Electronic modules

Electronic module - H9 - Voltmeter diagnostic (control panel) Access the HH MENU ZC as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. â&#x2C6;&#x2019; Select the MENU H9 with the UP or DOWN buttons (2), press the ENTER button (1) to access the MENU H9 program.

WLAPL4S55C1007A

WLAPL4S55C1004A

WLAPL4S55C1023A

- The top portion of the display ( (1) , 2 ) will show " ch0 ", 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 press the HOME button ( (1) , 1 ) to return to the HH menu where you can move between the various options. NOTE: You can enter this mode with the engine running. The box below shows the components you can test.

Comp. code

B-013

Description 5 volt power supply #1 5 volt power supply #2 Accelerator pedal.

ECU pin* X-460-1

Standard value 5000 mV

X-460-14

5000 mV

X-450 -5

500 mV (min) 4500 mV (max) 10 +12VP power supply X-460-20 1200 mV 25 B-023 Fuel level X-450-2 850 mV (full) 3760 mV (empty) 26 X-450-1 S-016 Operator present 3330 mV (oper. standing) switch 1660 mV (oper. seated) 90 B-015 Hand Throttle X-450-8 500 mV (min) 4500 mV (max) * - Refer to the ("System diagram" Wire harnesses - Electrical schema ADIC CONTROL PANEL CONTROL UNIT (55.100) ) of the panel control unit ADIC 84568014 22/03/2013

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Electrical systems - Electronic modules

Electronic module - HB - Display stored fault codes (control panel) Access the HH MENU ZC 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.

- The display, showing the programs, please see the figure, will show the fault codes recorded by the control unit. − # = 14900 Besides the fault number, the display will show in sequence: FIRST = 0 number of hours when the fault occurred the first time; LAST = 102 number of hours when the fault occurred the last time; COUNT = 134 number of times the fault has occurred. − You can select the various faults by pressing the UP and DOWN button ( (2) , 1). - After viewing the codes, press the HOME button ( (1) , 1 ) to return to the HH menu where you can move between the various options.

WLAPL4S55C1007A

WLAPL4S55C1024A

List of fault codes displayed by the ADIC ZC control unit E.C.R. (*) Description of fault Supply voltage at 5 V too high NO Supply voltage at 5 V too low NO Cranking sensing line shorted to + 12 V NO Cranking sensing line shorted to + 12 V NO Fuel tank level sender open circuit or short to voltage YES Fuel tank level sender short to ground YES Operator presence switch on for longer than 25 hours NO Pneumatic brake pressure sensor shorted to + 12 V or sensor not 14061 NO connected Seat switch signal short to voltage or open circuit 14093 NO Seat switch signal short to ground 14094 NO Pneumatic brake pressure sensor detected but not configured 14100 NO Front electronic lift present but not configured 14107 NO Rear electronic lift present but not configured 14109 NO Battery isolator switch on for longer than 30 s after turning the key onto 14200 NO power 14900 No transmission module on the line CAN NO (*) 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. Error code 14015 14016 14021 14022 14051 14052 14058

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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 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 Battery Voltage to ECM too High Battery Voltage to ECM too Low “ ECM 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 ECM 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 “ NEF : Rail Pressure Relief Valve – Did Not Open After Pressure Shock” “ F5C : 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 ECM Not Detected on CANbus or The engine data set registration information was not available from the engine within the time required Invalid ECM 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 84568014 22/03/2013

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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

+ 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 ECM Internal SPI Communication Error – CJ940 ECM EEPROM – Read Operation Failure ECM EEPROM – Write Operation Failure ECM EEPROM – Default Value Used ECM (Locked) Recovery Occurred “ ECM Recovery which is suppressed F5C : ECU internal: Visibility of Software Resets in DSM ” ECU Recovery (Visible) – Recovery Occurred ECM 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)” “C10 & C13 1ST P342: Cylinder 3 injector mechanical response fault (replace injector) ” “Rail Pressure Negative Deviation too High on Minimum Metering” “Fuel Metering Unit: maximum negative rail pressure deviation with metering unit on lower limit is exceeded (better description)” “C10 & C13 1ST P342: Cylinder 4 injector mechanical response fault (replace injector) ” “Rail Pressure below Minimum Limit in Controlled Mode” “Fuel Metering Unit: minimum rail pressure exceeded” “C10 & C13 1ST P342: Cylinder 5 injector mechanical response fault (replace injector)” “Rail Pressure above Maximum Limit in Controlled Mode” “Fuel Metering Unit: 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)

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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 3339 3350 3358 3361 3362 3368 3374 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

+ ERROR CODE DESCRIPTION Timeout of CAN message TSC1-VE Speed (When Active) Terminal 50 – Always On CAN Transmit Timeout ECM EEPROM – General Error Torque to Quantity Map – Not Plausible Info: Torque Limitation due to OBD Performance Limiter by Legislation Injection Quantity Adjustment failure – Invalid EEPROM Adjustment Value Checksum 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

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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 3666 3667 3668 3669 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

+ ERROR CODE DESCRIPTION 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 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 84568014 22/03/2013

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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 3741 3742 3743 3744 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

+ ERROR CODE DESCRIPTION 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 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

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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 3801 3802 3803 3808 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

+ ERROR CODE DESCRIPTION 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 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 84568014 22/03/2013

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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 3915 3916

+ ERROR CODE DESCRIPTION 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 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 1059 1063 1064 1065 1066 1067 1068

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 Reference voltage to 8 V load sensing pins, too high (> + 9 V), too low (< + 7 V) 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

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Electrical systems - Electronic modules

Electronic module - View list of transmission error codes Error code 2011 2012 2014 2015 2016 2017 2018 2019 2021 2024 2025 2026 2027 2028 2029 2030 2033 2035 2036 2037 2038 2039 2040 2041 2042 2043 2047 2048 2049 2051 2052 2053 2054 2055 2056 2057 2058 2059 2061 2065 2066 2067 2068 2069 2069 2081 2082 2083 2084 2085 2089 2090 2092

Description of fault Clutch pedal potentiometer signal too low Clutch pedal potentiometer signal too high Voltage from the gear neutral position switch is high Voltage from the gear neutral position switch is low Voltage from the range position switch (R1) is high Voltage from the range position switch (R1) is low Voltage from the range position switch (R2) is high Voltage from the range position switch (R2) is low Drive line harness disconnected All the clutches must be calibrated Engine speed (rpm) high Clutch D not calibrated Clutch C not calibrated Clutch B not calibrated Clutch A not calibrated Critical code on transmission Pressure on clutch A would not decrease Wheel speed too high Engine speed (rpm) low Clutch disengagement switch open circuit Clutch B solenoid valve short to + 12 V Clutch B solenoid valve open circuit or short to ground Inconsistent gear lever status switches Clutch A solenoid valve open circuit or short to ground Clutch A solenoid valve short to + 12 V Pressure on clutch B would not decrease Clutch disengagement switch set too high Clutch disengagement switch set too low Wheel speed sensor too high Oil temperature sensor open circuit Oil temperature sensor short circuit Reference voltage 5 V too high Reference voltage 5 V too low Shuttle lever forward drive switch voltage high Shuttle lever forward drive switch voltage low Shuttle lever reverse drive switch voltage high Shuttle lever reverse drive switch voltage low Shuttle Lever sw. disagree No seat safety switch transition in the last 25 hours of work Clutch C solenoid valve open circuit or short to ground Clutch D solenoid valve open circuit or short to ground Clutch D solenoid valve short to + 12 V Clutch C solenoid valve short to + 12 V Wheel speed sensor voltage too low (12X12 and 24X24 version) Wheel speed sensor voltage too low (20X20 version) Clutch A safety pressure switch open circuit or short to ground Clutch A safety pressure switch short circuit Clutch B safety pressure switch open circuit or short to ground Clutch B safety pressure switch short circuit No supply to pressure switches for clutches A and B Break in CAN communication between ADIC and the engine control unit Break in CAN communication between the ADIC and the XCM transmission control unit Short circuit to + 12 V from the clutch cut-out switch 84568014 22/03/2013

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Electrical systems - Electronic modules

Error code 2093 2094 2095 2097 2098 2430 2431 2450 2110 2111 2419 2422 2430 2431 2450

Description of fault Short circuit to + 12VF to the gear lever switch feed signal Short circuit to ground to the gear lever switch feed signal Clutch cut-out button jammed closed Short circuit to + 12 V to the discharge (dump) solenoid valve. Short circuit to ground or circuit open to the discharge (dump) solenoid valve. Creeper unit status switch voltage too low Creeper unit status switch voltage too high Configuration error Signal from the shuttle lever neutral switch low Signal from the shuttle lever neutral switch high Disagreement on the reactivity switch Configuration error on the multi-controller Voltage from the creeper unit switch low Voltage from the creeper unit switch high No match on the configuration

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Electrical systems - Electronic modules

Electronic module - View rear PTO error code listing Error code 5007 5008 5027 5033 5034 5035 5037 5043 5044 5045 5046 5047 5048

Description of fault PTO clutch solenoid valve short to + 12 V PTO clutch solenoid valve open circuit or short to ground PTO speed signal open circuit or short to + 12 V PTO cab normally closed switch open circuit Open circuit or short to ground to the PTO switches on the mudguards Short to + 12 V from the PTO switches on the fenders Cab rear PTO switch jammed on (normally off) Switch on fenders jammed on PTO speed signal short to ground Synchronized PTO switch open circuit or short to ground Short to + 12 V for synchronized PTO switch Synchronized PTO switch configuration error Switches on fenders not enabled

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Electrical systems - Electronic modules

Electronic module - View list of fourâ&#x2C6;&#x2019;wheel drive error codes Error code 6023

Description of fault Four-wheel drive clutch solenoid valve 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 7017

Description of fault Differential lock solenoid valve open circuit or short to ground

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Electrical systems - Electronic modules

Electronic module - HC - Clear all stored fault codes (control panel) Access the HH MENU ZC 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

WLAPL4S55C1025A

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 (control panel) Access the HH MENU ZC 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

WLAPL4S55C1026A

− The display will show the identification numbers of the control unit hardware release in sequence: 0738 − 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 (RW) H1 − CALIBRATIONS H2 − CALIBRATION VALUES DISPLAY H3 − OPTIONS H4 − SOFTWARE REVISION LEVEL H5 − CONTROL SWITCHES DIAGNOSTICS H6 − VEHICLE INFORMATION VIEW H7 − VEHICLE TEST H8 − DELETE DATA SAVED IN MEMORY H9 − VOLTMETER FUNCTIONS HB − SAVED FAULTS DISPLAY HC − DELETION OF SAVED FAULTS HE − FREQUENCY SIGNAL MONITORING HF − HARDWARE VERSION

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Electrical systems - Electronic modules

Electronic module - H1 - Calibration procedures 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 in an unobstructed area (in case of sudden 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. Check that the transmission oil temperature is 20 - 50 °C (68.00 - 122.00 °F) . 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. Access the HH MENU RW as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H1 with the UP or DOWN buttons (2), press the ENTER button (1) to access the MENU H1 program.

WLAPL4S55C1007A

WLAPL4S55C1027A

− Select the function of the MENU H1 with the UP or DOWN buttons ( (2) , 1 ).

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POWER SHUTTLE 12X12 AND 20X20 CLUTCH CALIBRATION TRANSMISSION Press the ENTER button (1) to access the transmission function of MENU H1 . − To calibrate the clutches the operator must be seated in the driving seat. − Press the clutch pedal, start up the engine and take it to a speed of 1250 - 1350 RPM ; − Engage the 1st gear (do not leave the gear lever in neutral) and range III, move the Power Shuttle control lever onto forward travel (not neutral) and release the clutch pedal NOTE: The clutches can also be calibrated without the tool 380000843 , simply proceed in the following manner. Power shuttle 12X12 and 20X20 Press and hold down the HOME button (1) while turning the key ON, within 10 s press and hold down the ENTER button ( (1) while starting. − If you have selected the MENU H1 (entering with the tool 380000843) you need to do the calibrations or turn the start switch to A (OFF). − The display will show CAL then the transmission oil temperature 50 °C (122.00 °F) .

WLAPL4S55C1007A

WLAPL4S55C1028A

WLAPL4S55C1029A

WLAPL4S55C1030A

NOTE: Clutch calibration is possible with both high and low oil temperatures, even if the display signals two alarm conditions to the driver: CL − in case of cold oil (below 20 °C (68.00 °F) ) CH − in case of hot oil (above 100 °C (212.00 °F) )

− Using the UP or DOWN button ( (2) , 4 ) select clutch A or B then keep the DOWN button ( (2) , 4) pressed to do the calibration. − The display will show in sequence: A = clutch to calibrate; I = vertical bar that, blinking, moves lengthwise: 280 = progressive calibration value: 295 = end calibration value that alternates with clutch A. − Release the DOWN button ( (2) , 4).

− Using the UP or DOWN button ( (2) , 4 ) select clutch B then keep the DOWN button ( (2) , 4) pressed to do the clutch calibration. − If a fault is found during calibration, the display will show the relevant error code U (see table at end of this chapter).

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Electrical systems - Electronic modules

NOTE: After selecting the clutch to calibrate with the UP or DOWN button ( (2) , 4 ) it is possible to start automatic calibration by pressing the UP button ( (2) , 4) for a few seconds then, automatically, the two clutches will be calibrated and, at the end, the central display will show End .

WLAPL4S55C1078A

WLAPL4S55C1031A

After calibrating all the clutches turn the switch (1) to A (OFF) to save the calibrations.

TRANSMISSION POWER SHUTTLE CLUTCH CALIBRATIONS WITH DUAL COMMAND (2 SPEED POWER SHIFT) FUNCTIONS 24X24. Press the ENTER button (1) to access the MENU H1 of the gearbox. − To calibrate the clutches the operator must be seated in the driving seat. − Press the clutch pedal, start up the engine and take it to a speed of 1250 - 1350 RPM ; − Engage the 1st gear (do not leave the gear lever in neutral) and range III, move the Power Shuttle control lever onto forward travel (not neutral) and release the clutch pedal

WLAPL4S55C1007A

NOTE: The clutches can also be calibrated without the tool 380000843 , just keep the buttons ( (2) and (3) ) of the HI and LO Dual Command (2 Speed Power Shift) pressed at the same time while starting up the machine.

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Electrical systems - Electronic modules

− If you have selected the MENU H1 (entering with the tool 380000843) you need to do the calibrations or turn the switch ( (1) , 9 ) to (A) (OFF).

WLAPL4S55C1032A

WLAPL4S55C1028A

WLAPL4S55C1029A

WLAPL4S55C1033A

− The display will show CAL then the transmission oil temperature 50 °C (122.00 °F) . NOTE: Clutch calibration is possible with both high and low oil temperatures, even if the display signals two alarm conditions to the driver: CL − in case of cold oil (below 20 °C (68.00 °F) ) CH − in case of hot oil (above 100 °C (212.00 °F) )

− Using button HI or LO ( (2) or (3) , 11 ) select clutch A then keep the button (LO) ( (3) , 11) pressed to do the calibration. − The display will show in sequence: A = clutch to calibrate; I = vertical bar that, blinking, moves from the left to the right: 280 = progressive calibration value: A / 295 = End calibration value that alternates with the clutch. − Release the button LO ( (3) , 11)

− Using the button HI ( (2) , 11 ) select the clutches b , C and d and keep the LO button ( (3) , 11) pressed to do the above-mentioned clutch calibration. − If a fault is found during calibration, the display will show the relevant error code U (see table at end of chapter).

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Electrical systems - Electronic modules

After selecting the clutch to calibrate with the HI or LO button ( (2) or (3) , 11 ) it is possible to start automatic calibration by pressing the HI button ( (2) , 11) for a few seconds then, automatically, the clutches will be calibrated and, at the end, the display will show End .

WLAPL4S55C1034A

WLAPL4S55C1031A

After calibrating all the clutches turn the switch (1) to (A) (OFF) to save the calibrations.

Calibration error code Code U17 U18 U19 U20 U21 U22 U23 U24 U25 U26 U31 U36 U37 CL CH

Description Operator present switch not on Start-up procedure not correct Oil temperature < 10 °C , calibration is not possible Handbrake is not set Engine speed too low Engine speed too high Control lever Power Shuttle in neutral Wrong range selection (the III range is not engaged) Gear lever in neutral Clutch pedal not pressed Tractor in motion Calibration value too high Calibration value too low Low oil temperature < 20 °C High oil temperature > 100 °C

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Electrical systems - Electronic modules

CALIBRATION LIFT − Preliminary operations. − Apply a weight of approx. 200 kg (440.92 lb) to the lift arms. − Lower lift arms and disconnect vertical rods supporting the automatic pick--up hitch (where fitted). − Rotate all the potentiometers: (1) - slip (2) - height limitation (3) - drop rate (4) - breadth of operation, all clockwise. NOTE: no limitations must be set during calibration. WLAPL4S55C1035A

WLAPL4S55C1036A

WLAPL4S55C1007A

WLAPL4S55C1037A

− Set the draft control ring nut (1) to 10 (the system must not read the draft during calibration).

Arm position control potentiometer calibration. - Press the ENTER button (1) to access the lift function of MENU H1 . - Press the clutch pedal, start up the engine and take it to a speed of 1200 - 1400 RPM

NOTE: The potentiometer can also be calibrated without the tool 380000843 , simply keep the lift, lower, rapid soil entry button (1) pressed on lifting, start the machine and, when the lift status indicator light ( (1), 21.) blinks, release the push--button.

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Electrical systems - Electronic modules

NOTE: There will be no message on the display, the only thing that will occur on entering calibration with the pushbutton ( (1) , 20 ) is the blinking of the warning light and....

WLAPL4S55C1038A

WLAPL4S55C1039A

WLAPL4S55C1040A

WLAPL4S55C1041A

NOTE: ......the performance monitor will show the fault code 1024 (run hydraulic lift auto-calibration). After potentiometer calibration, in this last case it is obviously necessary to calibrate the solenoid valves too.

Capture the lift arms with the position lever, then move it fully back. When the lift arms stop rising (you will hear the pressure relief valve trip for a moment) the value of the potentiometer is taken as the top calibration limit. The arms will lower slightly by approximately 4 % to protect the casing from mechanical damage. This position will in effect be 96 % of the travel but we consider it 100 %.

Move the position lever fully forwards, when the arms stop lowering the value of the arms control potentiometer is taken as the lower value.

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After calibrating turn the switch (1) to (A) (OFF) to save the calibrations.

WLAPL4S55C1031A

WLAPL4S55C1007A

WLAPL4S55C1037A

WLAPL4S55C1042A

Solenoid valve calibration. Press the ENTER button (1) to access the lift function of MENU H1 . â&#x2C6;&#x2019; Press the clutch pedal, start up the engine and take it to a speed of 1200 - 1400 RPM;

NOTE: The solenoid valves can also be calibrated without the tool 380000843 , simply keep the lift, lower, rapid soil entry button (1) pressed full down, start the machine and, when the lift status indicator light ( (1), 21.) blinks, release the push--button.

The display will show CAL .

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Capture the lift arms with the position lever (1) then move them fully back between 70 % and 90 % of the travel.

WLAPL4S55C1040A

WLAPL4S55C1043A

WLAPL4S55C1031A

On the display CAL will show 0 to indicate the start of calibration. During calibration the lift is automatically raised and lowered by a small amount 3 times, which takes 2 − 3 minutes. Each lifting and lowering operation is counted 0 − 1 − 2 on the display. When the display shows End calibration is over.

After calibrating turn the switch (1) to (A) (OFF) to save the calibrations.

NOTE: For the two calibrations of the lift it is advisable to calibrate them in sequence, first do the arms position control potentiometer and afterwards, without exiting calibration, calibrate the solenoid valves. Enter calibration either with program H1 of menu HH , or with button ( (1) , 27 ) pressed on rapid soil entry (fully down), then calibrate the lift by following the operations: − 5, is the one that appears on the display, − 1, 2, 3 and 4 to calibrate the arms lift potentiometer, − 6, 7 and 8 to calibrate the solenoid valves.

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Electronic module - H2 - View stored calibration values by the transmission (RW) Access the HH MENU RW 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

WLAPL4S55C1044A

WLAPL4S55C1045A

− 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 gearbox. − The display will show the current clutch calibration values. − You can select the various channels by pressing the UP and DOWN button ( (2) , 1 ).

Description

Channel Ch1 Ch2 Ch3 Ch4

Clutch Clutch Clutch Clutch

220 220 160 160

A B C D

480 480 480 480

Standard value mA mA mA mA

NOTE: The above values apply both to clutches A and B of the Power shuttle 12X12 and 20X20 version and to clutches A, B, C and D of the Power shuttle version with Hi Lo functions. The predefined calibration values are: clutches A and B − 275 mA clutches C and D − 250 mA The above values are the basic clutch values that, after deleting the memory in H8 , enable moving the machine.

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Electrical systems - Electronic modules

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 ).

WLAPL4S55C1046A

Channel Ch1 Ch2

Solenoid valve value Lifting Lowering

Standard value 20 - 80 mA 20 - 80 mA

NOTE: The predefined calibration values are: Lifting solenoid valve − 50 mA. Lowering solenoid valve − 50 mA. After deleting the memory with program H8 the predefined values in mA of the solenoid valves permit lift movement.

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Electrical systems - Electronic modules

Electronic module - H3 - Configurations and options of the transmission (RW) Access the HH MENU RW 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

WLAPL4S55C1047A

WLAPL4S55C1052A

− Select the MENU H3 options with the UP and DOWN buttons ( (2) , 1 ) and press the ENTER button ( (3) , 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.

− Select the gearbox submenu with the ENTER button (1) , 1 ). - Select the gearbox channel ( ch1 ), with the UP or DOWN button ( (1) , 1 ), the display will show these options: HI , LO and MID (pick-up value with gear shift). − Select the desired option with the UP and DOWN button ( (1) , 1 ).

LO MID HI

Clutch engagement time change speed threshold 5 km/h (3.11 mph) 6.5 km/h (4.04 mph) 13 km/h (8.08 mph) (default value)

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− Select the gearbox 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).

WLAPL4S55C1053A

NOTE: The above values apply both to clutches A and B of the Power shuttle 12X12 and 20X20 version and to clutches A, B, C and D of the Power shuttle version with Hi LO 24X24 functions. The default filling times are: clutches A and B − 60 ms clutches C and D − 40 ms − Select the gearbox channel ( ch6 ) with the UP and DOWN button ( (1) , 1 ). - The display will show: PS12 (for machines with Power shuttle 12X12 gearbox), PS20 (for machines with Power shuttle gearbox and creeper unit) PS24 (for machines with Power shuttle gearbox with Hi Lo functions). − Select the desired option with the UP and DOWN buttons ( (1) , 1 ).

WLAPL4S55C1054A

WLAPL4S55C1048A

− Select the gearbox channel ( ch7 ) with the UP and DOWN button ( (1) , 1 ). - The display will show: 34 (for machines with rear wheel diameter 34"), 38 (for machines with rear wheel diameter 38") Select the desired option using the UP and DOWN buttons ( (1) , 1). NOTE: The factory setting is 38"

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− Select the gearbox channel ( ch8 ) with the UP and DOWN button ( (1) , 1 ). - The display will show: 30 (for machines with gearbox at 30 km/h (18.64 mph) ), 40 (for machines with gearbox at 40 km/h (24.85 mph) ) − Select the desired option with the UP and DOWN buttons ( (1) , 1 ). NOTE: The factory setting is 40 km/h (24.85 mph)

WLAPL4S55C1049A

WLAPL4S55C1050A

WLAPL4S55C1051A

− Select the gearbox channel ( ch9 ) with the UP and DOWN button ( (1) , 1 ). - The display will show: YES (for machines with multi-controller), NO (for machines without multi-controller) - Select the desired option using the UP and DOWN buttons ( (1) , 1). NOTE: The factory setting is " NO ".

− Select the PTO submenu with the ENTER button (1) , 1 ). − Select the PTO channel ( ch2 ) with the UP and DOWN button ( (1) , 1 ). - The display will show: YES (for machines with buttons on the fenders), NO (for machines without buttons on the fenders) - Select the desired option using the UP and DOWN buttons ( (1) , 1). NOTE: The ch 1 is not used

− Select the PTO channel ( ch5 ) with the UP and DOWN button ( (1) , 1 ). - The display will show: YES (for machines with the synchronized power take−off), NO (for machines without the synchronized power take−off) - Select the desired option using the UP and DOWN buttons ( (1) , 1). NOTE: The ch 3 and ch 4 are not used.

WLAPL4S55C1055A

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− Select the electronic lift submenu with the ENTER button ( (1) , 1 ). − Select the electronic lift channel ( ch1 ) with the UP and DOWN button ( (1) , 1 ). - The display will show: dEF (for a machine on which nothing has ever been configured) Select the desired option using the UP and DOWN buttons ( (1) , 1) from among the ones in the following table:

WLAPL4S55C1056A

Pumps l./ US gal 63 l (16.64 US gal) or 80 l (21.13 US gal) 63 l (16.64 US gal) or 80 l (21.13 US gal) 63 l (16.64 US gal) 63 l (16.64 US gal)

EDC D.C. valve D.C. valve A.C. valve A.C. valve

Cylinders 1 Internal 1 Internal + 2 Suppl. 1 Internal 1 Internal + 2 Suppl.

Option A r0 A r2 B r0 B r0

NOTE: The " D.C. valve" and the closed center valve fitted with the spool valves Bosch . The " A.C. valve" and the open center valve fitted with the spool valves Kontakt . − Select the electronic lift channel ( ch2 ) with the UP and DOWN button ( (1) , 1 ). - The display will show: YES (for machines with the electronic lift enabled), NO (for machines with the electronic lift disabled), − Select the desired option using the UP and DOWN buttons ( (1) , 1).

WLAPL4S55C1057A

WLAPL4S55C1058A

− Select the electronic lift channel ( ch3 ) with the UP and DOWN button ( (1) , 1 ). - The display will show: YES (for machines with the slip function enabled), NO (for machines with the slip function disabled), − Select the desired option using the UP and DOWN buttons ( (1) , 1).

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Electronic module - H4 - View software revision level of the control unit (RW) Access the HH MENU RW 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

WLAPL4S55C1059A

− The display will show the identification numbers of the control unit software release in sequence: 1135 − 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 .

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Electrical systems - Electronic modules

Electronic module - H5 - Switch operation test - transmission control switches diagnostics (RW) Access the HH MENU RW 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

WLAPL4S55C1060A

− The display will show the number of the switch that has been operated. − Press the HOME button ( (1) , 1 ) to go back to the H5 menu where it is possible to move through the various HH menus.

VAR Code d1 d2 d4 d5 d6 d9 d12 d13 d15 d16 d17 d18 d20 d21 d22 d23 d24

Description EDC lowering switch on the mudguard EDC raising switch on the mudguard Lift−o−matic switch on rapid soil entry Lift−o−matic switch on lowering Lift−o−matic switch on raising Gear lever switch (G) LH brake pedal RH brake pedal Forward gear switch ( Power Shuttle lever) Reverse gear switch ( Power Shuttle lever) LO gear control button HI gear control button Clutch pressure switch A Clutch pressure switch B Creeper unit status switch shuttle lever neutral/run switch shuttle lever neutral switch

Electrical system code S-003 S-004

ECU pin(**) X-210 30

S-003 S-004

X-210 29

A-004

X-230 6

A-004

X-210 18

A-004

X-210 20

S-046 S-034 S-035 S-001

X-230 X-210 X-210 X-210

S-001

X-210 13

A-002 A-002 S-058 S-059 S-021 S-001

X-230 X-230 X-210 X-210 X-230 X-230

S-001

X-230 13

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4 22 23 12

11 10 21 28 16 15

Electrical systems - Electronic modules

Code d33 d38 d39 d44 d45 d48 d56 d63 d64 d65 d166 d169 d170 d171

Description Radar sensing line Differential lock permanently on Differential lock on automatic Engagement of power take-off (normally open) Engagement of power take-off (normally closed) Synchronized power take-off switch Four-wheel drive engagement Switch on mudguard (normally off) Switch on mudguard (normally on) PTO starting modulation switch Clutch discharge switch Range lever switch (R1) Range lever switch (R2) Reactivity switch

Electrical system code B-021 S-055

ECU pin(**) X-210 19 X-240 31

S-055

X-240 30

S-008

X-240 11

S-008

X-240 23

S-013

X-230 17

S-056

X-230 24

S-010 S-011

X-230 21

S-010 S-011

X-230 20

S-012

X-230 9

A-002 S-049 S-048 S-051

X-230 X-230 X-230 X-240

8 26 5 24-33

NOTE: Always make reference to the system diagram of the control units for this particular test, if a switch is connected to the control unit via another device, before creating a transition on the switch, make sure that the device between the switch and the control unit lets the signal pass. To make an example: the clutch pedal switch is tested only with the shuttle lever in forward or reverse drive, not in neutral (in this last situation the signal fails to reach the control unit, as it is a broken circuit).

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Electrical systems - Electronic modules

Electronic module - H6 - Vehicle information view on the transmission (RW) Access the HH MENU RW as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. − Select the MENU H6 with the UP and DOWN buttons (2), press the ENTER button (1) to access the MENU H6 program.

WLAPL4S55C1007A

WLAPL4S55C1061A

Select the ch1 channel, with the UP and DOWN buttons ( (2) , 1 ), the display will show: - PS24 for Power Shuttle with Hi LO 24X24 functions. − PS12 for Power Shuttle 12X12 − PS20 for Power Shuttle with the creeper unit 20X20 press the button ( (1) , 1) HOME to go back to the H3 menu where it is possible to move through the various HH menus.

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Electronic module - H7 - Vehicle test modes (RW transmission) Access the HH MENU RW 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. − You can select the various channels by pressing the UP and DOWN buttons (1). − Press the HOME button (1) to go back to the H7 menu where it is possible to move through the various HH menus.

WLAPL4S55C1007A

WLAPL4S55C1062A

WLAPL4S55C1063A

Clutch pedal switch − 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 the percentage of the clutch pedal travel and the switch status ( O for open, C for closed). NOTE: To view the state of the switch on the display ( C for closed and O for open) it is necessary to have the lever of the shuttle NOT in neutral, therefore, in forward or reverse gear. The switch must turn on upon releasing the pedal, between 11 - 13 % of the travel.

Range switch R1 and R2 − Select the ch2 Select the channel, with the UP and DOWN buttons ( (2) , 1 ), moving the range gear lever onto the various positions the display will show the corresponding range. − Following the condition of the range lever status switches.

Range I II III N

Switch R1 Closed Closed Open Open

Switch R2 Closed Open Closed Open

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Manual calibration of clutches with Power shuttle transmission with Hi Lo 24X24 functions. − To calibrate the clutches the operator must be seated in the driving seat. − Engage the 1st gear and range III, and switch on the machine. − Select the ch3 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. − Move the Power Shuttle control lever forwards to select clutch A....... − Press the clutch pedal and, using the UP and DOWN buttons ( (2) , 1), select the clutches A, C and D....... WLAPL4S55C1064A

WLAPL4S55C1065A

- ...or back to select clutch B. - ...or B, C and D. − Release the clutch pedal and press the UP and DOWN buttons ( (2) , 1 ) to increase or decrease the calibration value of each clutch.

NOTE: When optimizing the calibration values, driveline oil temperature should be warm to hot; preferably no lower than 40°C. NOTE: It is possible to test the modified calibration values by carrying out one of the following procedures. − As soon as the calibration value has been modified, engage the gear and range levers (do not leave them in neutral), release the clutch pedal above 95 % of the travel, put the shuttle lever into neutral and then put it into forward drive (for clutch A, C and D) and into reverse drive (for clutch B, C and D), you will hear the relevant clutch engage. − Switch off the machine. Clutches applied

Clutch to test A B C D

P.S. lever forward A B A A

+ + + +

C C C D

P.S. lever reverse

B+C B+C

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Electrical systems - Electronic modules

Manual calibration of clutches with Power shuttle 12X12 and 20X20 transmission. − To calibrate the clutches the operator must be seated in the driving seat. − Engage the 1st gear and range III, and switch on the machine. − Select the ch3 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. − Move the Power Shuttle control lever forwards to select clutch A or backwards to select clutch B.

WLAPL4S55C1066A

− Release the clutch pedal and press the UP and DOWN buttons ( (2) , 1 ) to increase or decrease the calibration value of each clutch NOTE: When optimizing the calibration values, driveline oil temperature should be warm to hot; preferably no lower than 40 °C (104.00 °F) . NOTE: It is possible to test the modified calibration values by carrying out one of the following procedures. − As soon as the calibration value has been modified, engage the gear and range levers (do not leave them in neutral), release the clutch pedal above 95 % of the travel, put the shuttle lever into neutral and then put it into forward drive (for clutch A) and into reverse drive (for clutch B), you will hear the relevant clutch engage. − Switch off the machine. Clutch to test A B

Clutch applied A B

Solenoid valve powered Drain Drain

Modify filling time of clutches with Power shuttle transmission with Hi LO 24X24 functions. − To make the modification the operator must be seated in the driving seat. − Engage the 1st gear and range III, and switch on the machine. − 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. − Move the Power Shuttle control lever forwards to select clutch A... − Press the clutch pedal and, using the UP and DOWN buttons ( (2) , 1), select the clutches A, C and D...... WLAPL4S55C1067A

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Electrical systems - Electronic modules

... or back to select clutch B. ..... or B, C and D. − Release the clutch pedal and press the UP and DOWN buttons ( (2) , 1 ) to increase or decrease the changed value of the filling times. NOTE: When optimizing the calibration values, driveline oil temperature should be warm to hot; preferably no lower than 40 °C (104.00 °F) . NOTE: It is possible to test the modified filling values by carrying out one of the following procedures WLAPL4S55C1068A

− As soon as the calibration value has been modified, engage the gear and range levers (do not leave them in neutral), release the clutch pedal above 95 % of the travel, put the shuttle lever into neutral and then put it into forward drive (for clutch A, C and D) and into reverse drive (for clutch B, C and D), you will hear the relevant clutch engage. − Switch off the machine. Clutches applied

Clutch to test A B C D

P.S. lever forward A B A A

+ + + +

C C C D

P.S. lever reverse

B+C B+C

Modify filling time of clutches with Power shuttle 12X12 and 20X20 transmission − To make the modification the operator must be seated in the driving seat. − Engage the 1st gear and range III, and switch on the machine. − 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. − Move the Power Shuttle control lever forwards to select clutch A or backwards to select clutch B. − Release the clutch pedal and press the UP and DOWN buttons ( (2) , 1 ) to increase or decrease the filling time for each clutch. NOTE: When optimizing the calibration values, driveline oil temperature should be warm to hot; preferably no lower than 40 °C (104.00 °F) . NOTE: It is possible to test the modified filling time values by carrying out one of the following procedures. − As soon as the calibration value has been modified, engage the gear and range levers (do not leave them in neutral), release the clutch pedal above 95 % of the travel, put the shuttle lever into neutral and then put it into forward drive (for clutch A) and into reverse drive (for clutch B), you will hear the relevant clutch engage. - Switch off the machine.

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WLAPL4S55C1069A

Electrical systems - Electronic modules

Clutch to test A B

Clutch applied A B

Solenoid valve powered Drain Drain

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Electrical systems - Electronic modules

Electronic module - H8 - Clear stored calibration information (EEPROM) on the transmission control unit (RW) Access the HH MENU RW 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.

WLAPL4S55C1007A

WLAPL4S55C1070A

WLAPL4S55C1071A

NOTE: On entering H8 you can delete the control unit memory on three levels: ALL − Deletes everything concerning the control units irrespective of function, Trasmisione − Deletes everything concerning the transmission ECU, four−wheel drive, power take−off and differential lock, EDC − Deletes everything concerning the electronic lift control unit. The values to delete are: calibration currents, filling times and pick-up values (these values must be set to the predefined ones) in addition all the fault codes. The control unit will create the fault codes 1024 and 2024. − Once you have decided with to delete everything or only a portion, enter the subsystems using the ENTER buttons ( (1) , 1 ). − 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.

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Electrical systems - Electronic modules

â&#x2C6;&#x2019; Turn the switch (1) to (A) (OFF).

WLAPL4S55C1021A

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Electrical systems - Electronic modules

Electronic module - H9 - Voltmeter diagnostic of the transmission control unit (RW) Access the HH MENU RW 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

WLAPL4S55C1072A

− You can select the various channels by pressing the UP and DOWN buttons ( (2) , 1 ). − The display will show the selected channel followed by the relevant measurement. − Press the HOME button ( (1) , 1) to go back to HH MENU .

Description

ECU pin(*)

10 11 14 15

Left-hand draft sensing pin Right-hand draft sensing pin Transmission oil temperature Gear lever switch (G)

X-210 10 X-210 9 X-210 14 X-230 4

Component code B-019 B-020 B-011 S-046

Range lever switch (R2)

X-230 26

S-049

Range lever switch (R1)

X-230 5

S-048

Solenoid - Dump Valve

CN3B−3

Work control potentiometer in position

X-210 3

Transmiss. A-004

Drop rate potentiometer

X-210 4

B-017

Height limit potentiometer

X-210 5

B-017

Sensitivity potentiometer

X-210 6

B-017

Slip limit potentiometer

X-210 1

B-017

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Standard value

~ 47 ~ 47 ~ 52 (at 25 °C (77.00 °F) ) ~ 30 (gear engaged) ~ 67 (gearbox in neutral) ~ 30 (gear in neutral and II) ~ 67 (range I and III engaged) ~ 30 (gear in neutral and I) ~ 67 (range II and III engaged) ~ 100 ~ 10 (arms down) ~ 88 (arms up) ~ 14 (minimum speed) ~ 84 (maximum speed) ~ 14 (maximum lift limit) ~ 84 (minimum lift limit) ~ 14 (minimum sensitivity) ~ 84 (maximum sensitivity) ~ 14 (minimum slip limit) ~ 84 (maximum slip limit)

Electrical systems - Electronic modules

Description

Draft setting potentiometer

X-210 8

Component code A-004

shuttle lever neutral switch

X-230 13

S-001

Clutch pedal potentiometer

X-230 7

B-014

Power supply fuse of pressure switch for clutches A and B — F-011 ( 5 A ) REV-- Switch

X-230 1

—

X-210 13

S-001

ECU pin(*)

Standard value

~ 14 (draft mode) ~ 89 (position mode) ~ 68 pressed ~ 31 released ~ 7 (pressed) ~ 89 (released) ~ 100

~ 68 (Shuttle lever in reverse) ~ 30 (Shuttle lever in neutral) 87 Forward switch X-210 12 S-001 ~ 68 (Shuttle lever on forward) ~ 30 (Shuttle lever in neutral) 91 X-210 2 B-012 NA Lift arm position Pot 99 Wheel speed sensor X-240 22 B-055 40 to 55 100 X-240 1 Y-001 Clutch A ~ 3 (clutch disengaged) ~ 70 (clutch engaged) 101 X-240 2 Y-002 Clutch B ~ 3 (clutch disengaged) ~ 70 (clutch engaged) 102 X-240 3 Y-003 Clutch C (24x24) ~ 3 (clutch disengaged) ~ 70 (clutch engaged) 102 X-240 3 Y-003 ~ 100 Discharge solenoid valve (12X12) 104 X-240 4 Y-004 Clutch D ~ 3 (clutch disengaged) ~ 70 (clutch engaged) 121 X-220 4 Y-005 Lifting solenoid valve ~ 0 (solenoid valve de--energized) ~ 66 (solenoid valve energized) 122 Lowering solenoid valve X-220 5 Y-006 ~ 0 (solenoid valve de--energized) ~ 66 (solenoid valve energized) 123 X-240 18 Y-009 ~ 100 Power take−off solenoid valve 130 X-230 6 A-004 ~ 0 pressed lift-o-matic switch on rapid soil entry ~ 99 released 134 Discharge switch X-230 8 A-002 ~ 68 not pressed ~ 88 pressed 135 HI switch X-230 10 A-002 ~ 68 not pressed ~ 88 pressed 136 X-230 11 A-002 ~ 68 not pressed LO switch ~ 88 pressed 137 X-240 19 B-022 40 to 55 PTO speed sensor 138 X-230 17 ~ 30 on Synchronized PTO switch S-013 ~ 67 off 167 X-230 9 ~ 68 not pressed PTO modulating switch S-022 * - Refer to the "System diagram" of the transmission control unit XCM (see Wire harnesses - Electrical schema TRANSMISSION CONTROL UNIT, ELECTRONIC LIFT, 4 DRIVING WHEELS, DIFFERENTIAL LOCK, POWER TAKE-OFF (55.100) )

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Electrical systems - Electronic modules

Electronic module - HB - Display stored fault codes on the transmission control unit (RW) Access the HH MENU RW 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

WLAPL4S55C1073A

WLAPL4S55C1074A

− 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.

− The display will show the fault codes logged in the control unit module. − You can select the various faults by pressing the UP and DOWN buttons ( (2) , 1 ). − Besides the fault number, the display will show in sequence: 300 - Number of hours when the fault occurred the first time; 340 - Number of hours when the fault occurred the last time; 3 Number of times the fault has occurred. − Press the HOME button ( (1) , 1 ) to go back to the HB menu where it is possible to access the various HH menus.

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Electrical systems - Electronic modules

Electronic module - HC - Clear all stored fault codes on the transmission control unit (RW) Access the HH MENU RW 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

WLAPL4S55C1075A

WLAPL4S55C1021A

− The central display will show FCL . − 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 transmission control unit (RW) Access the HH MENU RW 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

WLAPL4S55C1076A

− The display will show ch0 press the UP and DOWN button ( (2) , 1 ) the selected channel number followed by the related measurement. − Press the HOME button ( (1) , ) to go back to the HE menu where it is possible to move through the various HH menus.

ch Description ECU pin(*) Sens. code 3 Engine speed RPM B-010 CAN 4 X-240 19 B-022 PTO RPM speed 5 Wheel speed RPM X-240 22 B-005 6 Radar Hz X-210 33 B-021 (*) Refer to the "System diagram" of the transmission control unit XCM (see Wire harnesses - Electrical schema TRANSMISSION CONTROL UNIT, ELECTRONIC LIFT, 4 DRIVING WHEELS, DIFFERENTIAL LOCK, POWER TAKE-OFF (55.100) ).

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Electrical systems - Electronic modules

Electronic module - HF - View controller hardware information transmission (RW) Access the HH MENU RW as described in Electronic module - View HH MENU ACCESS (55.640) and proceed as follows. â&#x2C6;&#x2019; Select the MENU HF with the UP and DOWN buttons (1), press the ENTER button (1) to access the above-mentioned MENU HF .

WLAPL4S55C1007A

WLAPL4S55C1077A

â&#x2C6;&#x2019; The display will show the identification numbers of the control unit hardware release in sequence: 0638 = hardware module identification 04.00.00.00 = hardware module release identification 000.030.010.376 = serial number (printed on the control unit label). - At the end of the procedure you are automatically returned to HF where you can navigate among the various HH menus.

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Index Electrical systems - 55 Electronic modules - 640 Electronic module - H1 - Calibration procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Electronic module - H2 - View stored calibration values by the transmission (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Electronic module - H3 - Configurations and options control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Electronic module - H3 - Configurations and options of the transmission (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Electronic module - H4 - View software revision level of the control unit (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Electronic module - H4 - View software revision level control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electronic module - H5 - Switch operation test - transmission control switches diagnostics (RW) . . . . . . . . . . . . . 53 Electronic module - H5 - Switch operation test control switches (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Electronic module - H6 - Vehicle information view on the transmission (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Electronic module - H7 - Vehicle test modes (RW transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Electronic module - H8 - Clear stored calibration information (EEPROM) (control panel) . . . . . . . . . . . . . . . . . . . . 17 Electronic module - H8 - Clear stored calibration information (EEPROM) on the transmission control unit (RW) 61 Electronic module - H9 - Voltmeter diagnostic (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Electronic module - H9 - Voltmeter diagnostic of the transmission control unit (RW) . . . . . . . . . . . . . . . . . . . . . . . . 63 Electronic module - HB - Display stored fault codes (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electronic module - HB - Display stored fault codes on the transmission control unit (RW) . . . . . . . . . . . . . . . . . . 65 Electronic module - HC - Clear all stored fault codes (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Electronic module - HC - Clear all stored fault codes on the transmission control unit (RW) . . . . . . . . . . . . . . . . . . 66 Electronic module - HE - Display frequency inputs on the transmission control unit (RW) . . . . . . . . . . . . . . . . . . . . 67 Electronic module - HF - View controller hardware information (control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Electronic module - HF - View controller hardware information transmission (RW) . . . . . . . . . . . . . . . . . . . . . . . . . 68 Electronic module - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electronic module - View engine error codes list (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Electronic module - View list of differential lock error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Electronic module - View list of electronic lift error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Electronic module - View list of fourâ&#x2C6;&#x2019;wheel drive error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Electronic module - View list of transmission error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Electronic module - View rear PTO error code listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Electronic module - View HH MENU ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Electronic module - View HH MENU OF THE CONTROL PANEL (ZC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electronic module - View HH MENU OF THE TRANSMISSION (RW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Electronic modules - Fault code index Calibration U-code listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Transmission control system - 024

T5.105 T5.115 T5.95

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Contents Electrical systems - 55 Transmission control system - 024

FUNCTIONAL DATA Transmission control system Overview Range and gear position sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Transmission control system

Transmission control system - Overview Range and gear position sensors

WLAPL4S21C306F

(1). G gear sensing switch (S-046). (5). Mid-range selection fork control lever (II). (2). Range lever position sensor R1 (S-049). (6). Gear 1 and 2 selection fork control lever. (3). Range lever position sensor R2 (S-048). (7). Gear 3 and 4 selection fork control lever. (4).Slow (I) and fast (III) range selection fork control lever.

Adjustment check In the figure there is a diagram of the lever status switches. If the check is made during the phase of overhauling the gearbox, with the cab detached and with the aid of a tester switched onto ohmmeter, putting the rods at the ends of the switch, there must be the values in Ohms (ÎŠ) listed in the following table with the gear levers in their various positions.

SEZ21CAP3A-3

Gear sensing switch G (S-046) With the gear lever in Neutral position 1st

Switch status Closed Open

ÎŠ 560 2760

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Analog--digital conversion H9 (Channel 16) 67 30

Electrical systems - Transmission control system

Gear sensing switch G (S-046) With the gear lever in 2nd 3rd 4a

Switch status Open Open Open

ÎŠ 2760 2760 2760

R1 gear range sensing switch (S-049) AnalogWith the range -digital lever in conversion Switch status ÎŠ H9 (Channel 17) Neutral Open 2760 30 position Medium 560 67 Closed High 560 67 Closed Open Low 2760 30

Analog--digital conversion H9 (Channel 16) 30 30 30

R2 gear range sensing switch (S-048) Analog-digital conversion Switch status ÎŠ H9 (Channel 18) Open

2760

Open Closed Closed

2760 560 560

30 67 67

If the check must be made with the cab down, it is then difficult to use the tester at the ends of the various buttons, in the diagnostic programs HH MENU in H9 at channels Ch 15 (G) , Ch 22 (R1) and Ch 23 (R2) , it is perfectly possible to test the lever status buttons and the display will show the digital conversion of the above-mentioned tables. NOTE: At the time of overhaul it is wise to mount the sensors by resting them on the feelers. With program H9 it is possible to move the tractor. Drive over uneven ground to check that the sensors do not change state, this can occur on entering the programs HH and precisely in H9 at the channels corresponding to the sensors (see table).

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Index Electrical systems - 55 Transmission control system - 024 Transmission control system - Overview Range and gear position sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Cab hitch controls - 523

T5.105 T5.115 T5.95

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Contents Electrical systems - 55 Cab hitch controls - 523

FUNCTIONAL DATA Rear three-point hitch control potentiometers Component localisation from powerlift control, radar, control unit and traction sensors . . . . . . . . . . . . . . . 3

SERVICE Hitch electronic control panel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Electrical systems - Cab hitch controls

Rear three-point hitch control potentiometers - Component localisation from powerlift control, radar, control unit and traction sensors

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Electrical systems - Cab hitch controls

WLAPL4S35C601H

Arrangement of controls for electronic lifting gear control

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Electrical systems - Cab hitch controls

(1) . (2) . (3) . (4) . (5) . (6) .

- Raising and lowering lever, lifting link. - Grooved nut for towing or positioning work. - Lift-O-Matic switch ( Lift o Matic). - Potentiometer for slip control. - Potentiometer lifting height limitation. - Potentiometer for lowering speed controller.

(7) . - Speed controller for powerlift response sensitivity. (8) . - Telltale for lifting link, raising. (9) . - Telltale lift link, lowering. (10) . - Slip warning light. (11) . - Warning light, powerlift disabled and malfunction. (12) . Radar.

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Electrical systems - Cab hitch controls

WLAPL4S35C602H

Arrangement of radar, control unit and traction sensors

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Electrical systems - Cab hitch controls

(13) . - Lift-O-Matic switch on left mudguard. (14) . - Control unit powerlift with EHR EDC. (15) . - Display of lift link position, error codes and calibration.

(16) . - Left towing pin. (17) . - Potentiometer for lift link setting.

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Electrical systems - Cab hitch controls

Hitch electronic control panel - Remove To remove these assemblies, proceed as follows: 1.

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

WLAPL4S10C101A

MOIL12APL0042AA

MOIL12APL0044AA

Take out the screws (1) retaining the controls assembly.

Turn over the controls assembly and disconnect the connector of the mouse and of the hand throttle.

Inside, remove the four bolts retaining the lift controls mouse.

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Electrical systems - Cab hitch controls

Hitch electronic control panel - Install To reassemble the unit, proceed as follows: 1.

Refit the lift control mouse assembly on the lift control cover with the fixing screws.

Connect the connectors for the control mouse and the hand throttle.

Rest the unit on the right cover and secure it with the bolts.

Reconnect the battery negative cable, put the battery cover on and lower the right-hand steps.

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Index Electrical systems - 55 Cab hitch controls - 523 Hitch electronic control panel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hitch electronic control panel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Rear three-point hitch control potentiometers - Component localisation from powerlift control, radar, control unit and traction sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Rear three-point hitch electronic control system - 130

T5.105 T5.115 T5.95

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Contents Electrical systems - 55 Rear three-point hitch electronic control system - 130

TECHNICAL DATA Rear three-point hitch electronic control system General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Rear three-point hitch electronic control system External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T5.

Static description EDC mouse, potentiometer panel, warning lights panel . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dynamic description work modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Rear three-point hitch electronic control system Replace load sensing pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Draft sensor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Electrical systems - Rear three-point hitch electronic control system

Rear three-point hitch electronic control system - General specification

WLAPL4S35C601G

Type Check

with controlled position/draft and float setting via the transmission and services electronic control unit located under the panel behind the seat.

Controls

1. Electronic lift mouse, contains: position lever draft ring, lift/lower/fast soil entry button ( Lift â&#x2C6;&#x2019;oâ&#x2C6;&#x2019;Matic ) 2. LED panel, with lifting indicator light lowering indicator light lift disabled / failure warning light slip indicator light Ground position control

3. Potentiometers panel, with lifting limit down speed sensitivity Slip limit by means of two push-buttons (4) fitted on the rear fenders

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Electrical systems - Rear three-point hitch electronic control system

Rear three-point hitch electronic control system - External view T5.

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.

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Electrical systems - Rear three-point hitch electronic control system

Rear three-point hitch electronic control system - Static description EDC mouse, potentiometer panel, warning lights panel EDC CONTROL MOUSE. Position control lever. The position control lever (1) is used to determine the position of the lift arms. Move the lever fully forwards for the greatest depth or fully back to raise the lift arms completely.

WLAPL4S35C601A

WLAPL4S35C602A

WLAPL4S35C634A

Draft control ring. The draft control ring (1) is used to set a force of traction. The ring is marked with a scale from 0 to 10. Select 10 for the greatest draft resistance (position mode) and 0 for the minimum draft resistance.

Lift, lower, fast soil entry button ( Lift o Matic ) The Lift o Matic button (1) is used to raise and lower the lift during headland operations without touching the position lever. The second position at the bottom is used for fast soil entry: keep the button in this position if you want the implement to penetrate into the soil in less space, that is without reading the draft that would normally tend to raise the implement.

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Electrical systems - Rear three-point hitch electronic control system

SETTING POTENTIOMETERS PANEL Sensitivity adjustment potentiometer. It enables adjusting the sensitivity of the lift, turned fully clockwise there is the greatest sensitivity, the lift reacts by raising the arms with a minimum change in draft. Turned fully counter-clockwise there is the least sensitivity, the lift reacts after a much greater change in draft.

WLAPL4S35C603A

WLAPL4S35C604A

WLAPL4S35C605A

WLAPL4S35C606A

Lowering speed adjustment potentiometer. There is the greatest speed with the potentiometer turned fully clockwise. Turned fully counter-clockwise there is the lowest speed, with the potentiometer in the padlock position there is no lowering. This condition is considered transport safety; with the lift raised during transport, set the potentiometer on the padlock to be certain that it will not accidentally lower.

Height limit potentiometer. With the potentiometer turned fully clockwise there is no height limit, turned fully counter-clockwise the height reached by the lift arms is limited. Use this potentiometer to limit the height when using implements with the PTO shaft, preventing it from getting damaged, or when using implements that, with the lift arms fully up, interfere with the cab windows.

Slip limit setting potentiometer. With this potentiometer it is possible to set a slip percentage above which the system will raise the lift arms to decrease the draft and thus come back within the set percentage. This potentiometer is associated with the radar.

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Electrical systems - Rear three-point hitch electronic control system

INDICATOR LIGHT PANEL Slip warning light. The slip limit warning light is linked to the optional presence of the radar and the slip control potentiometer ( (1) , 7 ). this warning light comes on when the slip percentage is exceeded and the lift raises the arms to decrease the draft and thus come back within the set percentage.

WLAPL4S35C607A

WLAPL4S35C608A

Lift disabled and failure warning light. When this light comes on it can mean two things: A when the lamp blinks it means that the control unit has detected a fault in the lift's electronic control system and the display shows the fault code. B when it lights up steady, it means that the lift is not enabled, that is the cab controls do not mirror the position of the lift arms and so it is not possible to operate the lift directly with the position lever.

Arms lifting and lowering warning lights. The lifting (2) and lowering (1) warning lights are mounted in parallel with the respective solenoid valves so they signal the actual lifting and lowering of the lift arms.

WLAPL4S35C609A

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Electrical systems - Rear three-point hitch electronic control system

Rear three-point hitch electronic control system - Dynamic description work modes POSITION MODE When working in position mode the implement keeps the height determined by the position lever and is not affected by the force of traction. Set the draft adjustment ring (1) onto 10 and as a result the system will not read the force of traction. Use the position lever (2) to find the desired height. At the headland, use the Lift o Matic button to raise the implement without using the position lever. After repositioning the tractor, press the Lift o Matic button down to enter the ground.

WLAPL4S35C610A

WLAPL4S35C611A

WLAPL4S35C603A

DRAFT MODE Working in draft mode (taking the example of plowing) is a case where the implement maintains the depth determined by the position lever however the system gives priority to the force of traction; if this, set with the ring ( (1) , 1 ), exceeds the setting, the system will raise the lift arms to find a lower draft making the value return to the set one.At first, set the draft control ring ( (1) , 1 ) on 10. Use the position lever ( (2) , 1 ) to find the working depth. Now set the draft with the ring ( (1) , 1) until the system starts raising the arms, then set the draft on the value immediately lower. When working in draft mode, the central display will show the letters dr ( draft). The work will now be done at the depth set with the lever ( (2) , 1 ) and at the draft set with the ring ( (1) , 1 ). In the same way, if the draft decreases the system will tend to lower the arms to find a greater draft. This situation of the implement entering the soil will be prevented by the position lever that will not allow a greater working depth than the setting. This mode is usually called mixed. If the system calls up the lift too often, it causes too great a change in the soil, making it difficult to drive the tractor because of the jolting with the arms being operated. It is possible to use the sensitivity potentiometer (1) to select a lower sensitivity so as to call up the lift with greater changes in draft. At the headland, use the Lift o Matic button to raise the implement without using the position lever. After repositioning the tractor, press the Lift o Matic button fully down (rapid soil entry) to enter the soil without the system, during lowering, failing to read the draft, for soil entry in less space.

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Electrical systems - Rear three-point hitch electronic control system

FLOAT MODE Working in float is done with implements that follow the contours of the ground with wheels, rollers or runners. Set the draft adjustment ring (1) onto 10 and as a result the system will not read the force of traction.Move the position lever (2) fully forwards onto position 0 (lift arms completely lowered). At the headland, use the Lift o Matic button to raise the implement without using the position lever. After repositioning the tractor, press the Lift o Matic button down to lower it.

WLAPL4S35C610A

NOTE: In the operating modes described above, the following potentiometers can operate: drop rate limitation during transport, using it for transport safety, lift limit when working with implements at the PTO to avoid damaging the drive shaft or when working with reversible plows to prevent them interfering with the rear cab window, slip percentage when working on slippery ground. (See “SETTING POTENTIOMETERS PANEL” in Rear three-point hitch electronic control system - Static description EDC mouse, potentiometer panel, warning lights panel (55.130)

LIFT RESTORATION Every time: − the raise lower external buttons on the fenders are used, − with the engine off, move the lift position control lever the lift disabled warning light (1) will come on.

WLAPL4S35C608A

WLAPL4S35C601A

To put the lift arms back in phase with the position lever it is necessary (clearly with the engine running) to move the lever forwards or backwards until the lift arms move and the related warning light goes out.

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Electrical systems - Rear three-point hitch electronic control system

DYNAMIC RIDE CONTROL When transporting equipment, implement bounce can lead to lack of steering control at speeds. By turning the drop rate control (1) fully counter-clockwise (onto the padlock position) and using the raise lower and fast soil entry button ( (3) , 4 ) to raise the implement, the smooth ride device comes into operation. The smooth ride device comes into operation above 8 km/h (5 mph) : when the speed is higher than this, the lift lowers by a minimum percentage and the system uses the lifting and lowering solenoid valves to counter the swings. If the speed falls under this value, the lift raises to the maximum height set with the lift limit potentiometer ( (1) , fig. 13). (See â&#x20AC;&#x153;LIFTING LIMIT POTENTIOMETER" in Rear threepoint hitch electronic control system - Static description EDC mouse, potentiometer panel, warning lights panel (55.130)

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WLAPL4S35C604A

Electrical systems - Rear three-point hitch electronic control system

Rear three-point hitch electronic control system - Replace load sensing pin Removal 1.

Lower the hydraulic lift arms

Disconnect the connectors of the load sensing pin (1) , situated on the top of the rear axle housing.

WLAPL4S35C628A

WLAPL4S35C629A

WLAPL4S35C630A

Remove the guard by unscrewing the two fixing screws (1) .

Remove the two bolts from the retaining bracket and extract the pin.

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Electrical systems - Rear three-point hitch electronic control system

If necessary, use the other holes for screws size 10 mm (0.3937 in) (1) and the screws (2) to extract the pin from the housing hole.

WLAPL4S35C631A

WLAPL4S35C632A

WLAPL4S35C633A

WLAPL4S35C629A

Installation 1.

Install the pin making sure that it is located with the three flat sides facing towards the front of the tractor.

Install the retaining bracket with the open end facing the rear of the tractor.

Tighten the retaining bolts to the prescribed torque 48 NÂˇm (35.40 lb ft) .

Refit the guard and tighten its screws to 23 NÂˇm (16.96 lb ft) .

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Electrical systems - Rear three-point hitch electronic control system

Draft sensor - Remove Proceed as follows: 1.

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

MOIL12APL0051AA

MOIL12APL0052AA

Disconnect the lift arm position potentiometer connection, detach and remove the tie-rod (1).

â&#x20AC;&#x201C; Unscrew the screws (1) and remove the potentiometer/support bracket assembly from the lift. Take out the screws (2) and the circlip on the pin, detach the potentiometer (3) from the lever.

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Electrical systems - Rear three-point hitch electronic control system

Draft sensor - Install To refit the potentiometer, proceed as follows: 1.

Mount the potentiometer on the lever.

Mount the potentiometer/support assembly on the lift box.

Mount the potentiometer-lift arm connection tie-rod.

Connect the electrical connection to the potentiometer.

Connect the negative cable to the battery, put the cover back on and lower the right-hand steps.

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Index Electrical systems - 55 Rear three-point hitch electronic control system - 130 Draft sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Draft sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Rear three-point hitch electronic control system - Dynamic description work modes . . . . . . . . . . . . . . . . . . . . . . . . . 8 Rear three-point hitch electronic control system - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T5.

Rear three-point hitch electronic control system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear three-point hitch electronic control system - Replace load sensing pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rear three-point hitch electronic control system - Static description EDC mouse, potentiometer panel, warning lights panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - 55 Warning indicators, alarms, and instruments - 408

T5.105 T5.115 T5.95

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Contents Electrical systems - 55 Warning indicators, alarms, and instruments - 408

FUNCTIONAL DATA Instrument cluster Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Dynamic description display information and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dynamic description (ADIC) programmable display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Dynamic description dashboard/display brightness adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Dynamic description Speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Dynamic description implement width calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Dynamic description programming maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Dynamic description audible warning on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Dynamic description setting units of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 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 - Overview

DCAPLT5NE075S3F

The indicator lights on the control panel inform you of the operational condition of the machine. Some of these indicate faults arising during operation. An indicator light coming on may be followed by a continuous or intermittent buzzer. Depending on the severity of the trouble, the alarm will sound.

Trailer direction indicator light (green) 1

This indicator light flashes together with the tractor/trailer direction indicators, if the first trailer is connected

Trailer direction indicator light (green) 2

This indicator light flashes together with the tractor/trailer direction indicators, if the second trailer is connected

Fullâ&#x2C6;&#x2019;beam headlights (blue)

Side lights (green)

This indicator light will illuminate when the tractor lights are switched to high beam.

This indicator light is illuminated when the tractor lights are turned on.

Stop warning light (red) 5

If the red â&#x20AC;&#x153;Stopâ&#x20AC;? warning light comes on, switch off the tractor immediately and look for the cause. A warning symbol will appear on the display (30) confirming the location of the fault.

Engine coolant temperature gauge This instrument indicates the temperature of the engine coolant.

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Indicator lamp (amber) 7

This indicator light comes on and the display shows a warning symbol (30). The light blinks for 4 seconds, after which the symbol on the display disappears and the indicator light stays on steady. To display the fault, you need to go to the menu. Stop the tractor and investigate the cause of the trouble.

High range engagement indicator (green) 8

Lights up when the high gear range is selected (tractors with Power-Shuttle/Dual Command (2 Speed Power Shift) transmission only).

Parking brake warning light (red) 9

This lights up when the key start switch is turned ON with the parking brake applied. If the key-start switch is turned OFF and the parking brake is not applied, or the operator leaves the seat without applying the parking brake, a warning buzzer will sound for approximately 10 seconds or until the parking brake has been applied.

Trailer brakes application pressure warning light (red) 10

(Italy only) - This warning light will illuminate to indicate that the delivery pressure of the oil for actuating the trailer brake is low.

Brake pedals not latched warning light (red). 11

(not available for all markets) The indicator lights up to signal when brake pedal latching is not blocked. NOTE: This warning light is only active for markets that require signaling failed brake pedal latching.

Engine oil pressure warning light (red) 12

Engine oil pressure indicator light (red) - This indicator light together with the red (5). â&#x20AC;?Stopâ&#x20AC;? indicator light indicates the engine oil pressure is too low. Stop the engine and investigate the cause. NOTE: With low engine oil pressure, this warning light illuminates when the start switch is in the contact position B (supply to accessories - ignition).

Not used.

Cold start device (amber) The indicator lights up when the glow plugs are turned on by the key start switch.

Right direction indicator (green) 15

This indicator light flashes at the same time as the tractor's right direction indicator. With the tractor running, if the turn signal is not switched off within 20 seconds an intermittent alarm comes on. This audible warning comes on if the direction indicator is not turned off within 5 minutes with the tractor stationary.

Not used. Filter clogging warning light (DPF) (green)

The warning light is on steady with automatic regeneration of the disabled particulate filter. It flashes during the phase of particulate filter regeneration.

Alternator charging warning light (red) A steady light indicates that the alternator is not charging the battery.

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Fuel reserve (amber)

Not Used

Fuel Level Gauge

The light comes on when the tractor needs refueling.

This instrument shows the fuel level in the tank.

Automatic four-wheel drive engaged warning light (green) 22

This warning light comes on when the automatic four−wheel drive engagement function is activated.

Engine Tachometer

Differential lock (amber)

Four−wheel drive (green)

Indicates the engine rpm. Each subdivision of the graduated scale represents 100 revs/minute.

This warning light comes on when the differential lock is engaged.

This indicator light will illuminate when the drive to the front wheels is engaged.

Rear power take−off warning light (yellow) 26

Lights up when the engine is running and the rear power take-off is engaged. The warning light, from being on steady, starts blinking when the power take−off exceeds the maximum permissible number of revs.

Front power take−off warning light (yellow) This warning light comes on when, with the engine running, the front PTO is engaged.

Left direction indicator (green) 28

This indicator light flashes at the same time as the tractor's left direction indicator. With the tractor running, if the turn signal is not switched off within 20 seconds an intermittent alarm comes on. This audible warning comes on if the direction indicator is not turned off within 5 minutes with the tractor stationary.

Work lights (amber) This warning light illuminates when the work lights are switched on.

Information Display 30

The display shows information on the operational condition of the machine and highlights any trouble in the form of symbols or error codes.

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Electrical systems - Warning indicators, alarms, and instruments

Engine Tachometer The rev counter (1) indicates the engine rpm. Each division on the scale represents 100 rev/min., therefore, with the needle indicating 20 , the engine is running at 2000 RPM.

Engine speed ATTENTION: Never use the engine continuously for a long time at speeds between 2500 - 3000 RPM (yellow area on the speedometer) to avoid damage to the engine and definitely never exceed 3000 RPM (red area on the speedometer). For appropriate use, always operate under the speed corresponding to 2300 RPM.

DCAPLT5NE077S3A

DCAPLT5NE003S3F

DCAPLT5NE004S3F

Engine coolant temperature gauge The temperature display (1) indicates the temperature of the engine coolant. â&#x20AC;˘ blue area = normal temperature; â&#x20AC;˘ red area = temperature too high. In this case, slow the engine to idling speed (without stopping the engine) and, if the light stays on, have the cooling system checked.

Fuel Level Gauge This instrument (1) indicates the level of diesel in the tank and only works when the ignition key is turned onto ON.

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Electrical systems - Warning indicators, alarms, and instruments

Central display The central liquid crystal display provides the operator with a range of information 1. Front or rear power takeâ&#x2C6;&#x2019;off speed Front or rear lift position Slip Data displayed by pressing and releasing the button ENTER (A) 2. Tractor direction. 3. Speed of the vehicle in Km/h or MPH 4. Tractor working hour meter

DCAPLT5NE005S3F

DCAPLT5NE088S3A

5. Kilometres travelled Area worked Area worked per hour Battery voltage Data displayed by pressing the arrow buttons up or down (B) When necessary, warning and error messages Programming menu (see specific chapter)

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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 ZC control panel is on ( YES ) you can see: Odometer Worked area Estimated hourly area Battery voltage If the PMU option in H3 of the ZC 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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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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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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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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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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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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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 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 Driveline oil temperature it to cool. Restart work and too high. The tractor will be if the warning continues, Critical stopped automatically in a switch off the engine again, short time. check the oil level of the 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. 84568014 22/03/2013

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Instrument cluster - Dynamic description Speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Instrument cluster - Dynamic description audible warning on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Instrument cluster - Dynamic description dashboard/display brightness adjustment . . . . . . . . . . . . . . . . . . . . . . . . 12 Instrument cluster - Dynamic description display information and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Instrument cluster - Dynamic description fault codes display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Instrument cluster - Dynamic description implement width calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Instrument cluster - Dynamic description oil change counter reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Instrument cluster - Dynamic description programming maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Instrument cluster - Dynamic description setting hours worked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Instrument cluster - Dynamic description setting units of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Instrument cluster - Overview warnings on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Instrument cluster - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Instrument cluster - Static description alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Electrical systems - 55 FAULT CODES - DTC

T5.105 T5.115 T5.95

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Contents Electrical systems - 55 FAULT CODES - DTC

DIAGNOSTIC 1004-Wheel Speed Sensor Signal Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1008-Raise / Work Switch Failure (Command Arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1017-Left Hand Load Sensing Pin Signal Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1018-Both Load Sensing Pins Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1019-Load Sensing Pin 8V Reference Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1020-Load Sensing Pin 8V Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1024-Perform The Hydraulic Lift Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1028-Lift Arm Position Sensing Control Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1029-Hydraulic Control Valve Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1031-Chassis Harness Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 1063-EDC Hydraulic Valve Lower Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1064-EDC Hydraulic Valve Raise Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 1065-EDC Hydraulic Valve Lower Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1066-EDC Hydraulic Valve Raise Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2052-Oil Temperature Sensor - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 3293-Fuel Metering Unit: maximum positive deviation of rail pressure exceeded . . . . . . . . . . . . . . . . . . . 43 3406-ECU Power stages: Over temperature error on the Turbocharger PWM output power stage . . . . 44 3699-EEPROM: Error in EEPROM block EEPData1, SD correction can not be calculated . . . . . . . . . . 47 3710-Lambda sensor: Fault to indicate dynamics of the sensor signal too small . . . . . . . . . . . . . . . . . . . 48 3711-SCB error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 3721-Lambda sensor: Fault check to indicate SPI chip error of lambda sensor . . . . . . . . . . . . . . . . . . . . 54 3766-Diesel particulate filter pressure sensor: Fault check for the pressure sensor plausibility . . . . . . . 55 3796-Diesel particulate filter pressure sensor hose line error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 3825-Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 3841-Diesel particulate filter upstream temperature sensor shorted to low source . . . . . . . . . . . . . . . . . . 60 5033-Rear PTO Cab Normally Closed Switch Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 5035-Rear PTO Fender Switch Input Short To 12V+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 CH-HOT OIL WARNING: displayed above 100 degrees C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 CL-COLD OIL WARNING: displayed below 20 degrees C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 U17-Seat switch not activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 U18-Correct start up procedure not used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 U19-Oil temperature < 10 Â°C, calibration is not possible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 84568014 22/03/2013

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U20-Parking brake not applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 U21-ERPM is below 1250, increase throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 U22-ERPM is above 1350, reduce throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 U23-Shuttle lever is in neutral, shift lever to forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 U24-Incorrect range selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 U25-Main gear lever is in neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 U26-Clutch pedal is not up, release clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 U31-Wheel speed sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 U36-Calibration value too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 U37-Calibration value too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 [ADIC] - 14015-5V supply voltage - too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 [ADIC] - 14016-5V supply voltage - too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 [ADIC] - 14021-Cranking line - shorted to +12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 [ADIC] - 14022-Cranking line - shorted to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 [ADIC] - 14051-Fuel tank level sender open circuit or short to high voltage . . . . . . . . . . . . . . . . . . . . . . . . 89 [ADIC] - 14052-Fuel tank level sender short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 [ADIC] - 14058-Seat Switch Closed for Over 25 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 [ADIC] - 14093-Seat switch signal short to + 12V or open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 [ADIC] - 14094-Seat switch signal short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 [ADIC] - 14100-Pneumatic brake pressure sensor detected but not configured . . . . . . . . . . . . . . . . . . . . 98 [ADIC] - 14107-Front hitch present but not configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 [ADIC] - 14108-Rear PTO sensor present but not configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 [ADIC] - 14109-EDC present but not configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 [ADIC] - 14200-Battery isolator switch closed to battery at Key ON for more than 30 seconds . . . . . . 102 [ADIC] - 14900-Control unit (XCM) disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 [ADIC] - 14901-Engine controller missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 [ADIC] - 3001-Foot throttle sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 [ADIC] - 3002-Foot throttle sensor - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 [ADIC] - 3003-Foot throttle sensor - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 [ADIC] - 3126-Hand throttle - channel 1 signal above range max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 [ADIC] - 3127-Hand throttle - channel 1 signal below range min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 [CCU] - 1070-Electronic Draft Control (EDC) - ram configuration not set . . . . . . . . . . . . . . . . . . . . . . . . . 120 [ECU] - 3006-Coolant temperature signal - signal not plausible (compared with engine oil temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 [ECU] - 3007-Coolant temperature sensor - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . 124 [ECU] - 3008-Coolant temperature signal - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . 127 [ECU] - 3010-Boost temperature sensor - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . 130 [ECU] - 3011-Boost temperature sensor - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . 134 [ECU] - 3015-Fuel temperature sensor - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . 138 [ECU] - 3016-Fuel temperature sensor - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 [ECU] - 3019-Boost pressure sensor - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 [ECU] - 3024-Atmospheric pressure sensor - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . 146 [ECU] - 3025-Atmospheric pressure sensor - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . 147

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[ECU] - 3027-Oil pressure sensor: Defect fault check for plausibility from digital sensor . . . . . . . . . . . . 148 [ECU] - 3037-Boost pressure sensor - signal low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 [ECU] - 3051-Battery voltage to ECU - voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 [ECU] - 3052-Battery voltage to ECU - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 [ECU] - 3059-ECU main relay: Stuck main relay error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 [ECU] - 3063-Cylinder1 - injector cable short circuit (high side to ground) . . . . . . . . . . . . . . . . . . . . . . . . 159 [ECU] - 3071-Cylinder 3 - injector cable short circuit (high side to ground) . . . . . . . . . . . . . . . . . . . . . . . 162 [ECU] - 3079-Cylinder 2 - injector cable short circuit (high side to ground) . . . . . . . . . . . . . . . . . . . . . . . 164 [ECU] - 3083-Cylinder 4 - injector cable short circuit (high side to ground) . . . . . . . . . . . . . . . . . . . . . . . 166 [ECU] - 3088-Crankshaft sensor - no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 [ECU] - 3089-Crankshaft sensor - invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 [ECU] - 3090-Camshaft sensor - no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 [ECU] - 3091-Camshaft sensor - invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 [ECU] - 3093-Offset between camshaft and crankshaft - outside boundaries . . . . . . . . . . . . . . . . . . . . . 181 [ECU] - 3096-ECM Busoff on vehicle CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 [ECU] - 3102-Rail pressure sensor CP3 - signal below range min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 [ECU] - 3104-Rail pressure relief valve - open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 [ECU] - 3105-Rail pressure relief valve - pressure shock requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 [ECU] - 3106-Pressure relief valve reached maximum allowed opening count . . . . . . . . . . . . . . . . . . . . 190 [ECU] - 3107-Fuel metering unit - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 [ECU] - 3108-Fuel metering unit - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 [ECU] - 3112-Rail pressure sensor CP3 - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . 195 [ECU] - 3137-Metering unit - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 [ECU] - 3139-Metering unit signal range check - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 [ECU] - 3140-Metering unit signal range check - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 [ECU] - 3141-Fuel flow setpoint too low - fuel metering unit: leakage is detected based on fuel quantity balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 [ECU] - 3146-Water sensor in the fuel filter : Water in fuel level sensor defect detection . . . . . . . . . . . 204 [ECU] - 3157-Engine control unit (ECU) not detected on the CANbus or the engine dataset registration information was not available from the engine within the time required . . . . . . . . . . . . . . . . . . . . . . . . . . 206 [ECU] - 3158-Invalid ECM checksum (the engine dataset does not match the dataset registered for this machine. Register the new dataset if the dataset has just been updated) . . . . . . . . . . . . . . . . . . . . . . . . 208 [ECU] - 3166-Fuel filter heater relay - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 [ECU] - 3167-Fuel filter heater relay - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 [ECU] - 3168-Fuel filter heater relay - no load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 [ECU] - 3169-Fuel filter heater relay - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 [ECU] - 3176-Fuel metering unit: Set point of metering unit in overrun mode not plausible . . . . . . . . . 217 [ECU] - 3177-Engine overspeed detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 [ECU] - 3179-Timeout of CAN message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 [ECU] - 3180-Timeout of CAN message VCM2EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 [ECU] - 3188-Injector cylinder 1 warning - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 [ECU] - 3192-Injector cylinder 2 warning - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 [ECU] - 3196-Injector cylinder 3 warning - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 [ECU] - 3200-Injector cylinder 4 warning - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 84568014 22/03/2013

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[ECU] - 3210-Bank 1 - general short circuit on injection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 [ECU] - 3218-Bank 2 - general short circuit on injection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 [ECU] - 3230-Injection processor (CY33X) error - SPI communication failure . . . . . . . . . . . . . . . . . . . . . 243 [ECU] - 3235-Number of injections limited - by charge balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 [ECU] - 3236-Number of injections limited - by quantity balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 [ECU] - 3237-Number of injections limited - by software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 [ECU] - 3238-ECU power stages: Errors of the power failure detection of CY320 . . . . . . . . . . . . . . . . . 247 [ECU] - 3239-Engine controller EEPROM - read operation failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 [ECU] - 3240-Engine controller EEPROM - write operation failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 [ECU] - 3241-Engine controller EEPROM - read/write error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 [ECU] - 3242-ECU internal: Visibility of software resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 [ECU] - 3243-ECU internal: Visibility of software resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 [ECU] - 3244-ECU recovery (visible) - recovery occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 [ECU] - 3245-ECM processor - watchdog not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 [ECU] - 3252-Controller watchdog - SPI communication failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 [ECU] - 3253-Analog digital converter (ADC) : Diagnostic fault check to report the error in voltage ratio in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 [ECU] - 3255-Analog digital converter (ADC) : Diagnostic fault check to report the ADC test error . . . 257 [ECU] - 3256-Analog Digital Converter (ADC) : Diagnostic fault check to report the NTP error in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 [ECU] - 3265-Overrun monitoring - injection time too long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 [ECU] - 3266-Engine speed : Diagnostic fault check to report the engine speed error . . . . . . . . . . . . . . 260 [ECU] - 3283-Sensor supply voltage 2 - high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 [ECU] - 3285-Sensor supply voltage 3 - high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 [ECU] - 3301-Fuel metering unit: Maximum negative rail pressure deviation with metering unit on lower limit is exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 [ECU] - 3305-Fuel metering unit: Minimum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 [ECU] - 3309-Fuel metering unit: Maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 [ECU] - 3334-Timeout of CAN message TSC1-PE torque (when active) . . . . . . . . . . . . . . . . . . . . . . . . . 268 [ECU] - 3335-Timeout of CAN message TSC1-PE torque (when inactive) . . . . . . . . . . . . . . . . . . . . . . . . 270 [ECU] - 3338-Timeout of CAN message TSC1-VE speed (when inactive) . . . . . . . . . . . . . . . . . . . . . . . . 272 [ECU] - 3339-Timeout of CAN message TSC1-VE speed (when active) . . . . . . . . . . . . . . . . . . . . . . . . . 274 [ECU] - 3358-CAN transmit timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 [ECU] - 3361-ECM EEPROM - general error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 [ECU] - 3362-Torque to quantity map - not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 [ECU] - 3368-Info: Torque limitation due to OBD performance limiter by legislation . . . . . . . . . . . . . . . . 280 [ECU] - 3374-Injection quantity adjustment failure - invalid EEPROM adjustment value checksum . . 281 [ECU] - 3402-Rail pressure sensor: Maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 [ECU] - 3405-ECU Power stages: Open load temperature error on the turbocharger PWM output power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 [ECU] - 3408-Lambda sensor: Oxygen concentration implausibly high . . . . . . . . . . . . . . . . . . . . . . . . . . 286 [ECU] - 3409-Oil pressure switch: Oil pressure too low (at engine running) . . . . . . . . . . . . . . . . . . . . . . . 289 [ECU] - 3410-Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 [ECU] - 3411-Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

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[ECU] - 3414-Short circuit in glow plug 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 [ECU] - 3415-Short circuit in glow plug 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 [ECU] - 3416-Short circuit in glow plug 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 [ECU] - 3417-Short circuit in glow plug 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 [ECU] - 3418-ECU power stages: short circuit to battery error on the turbocharger PWM output power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 [ECU] - 3419-ECU power stages: Short circuit to ground error on the turbocharger PWM output power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 [ECU] - 3420-CAN Bus received frames: DFC of auxiliary engine shutdown switch message . . . . . . . 310 [ECU] - 3425-Turbocharger: Over boost deviation at P2 too high in pressure charger regulator . . . . . 311 [ECU] - 3427-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 [ECU] - 3428-Diesel particulate filter pressure sensor: Not plausibility error . . . . . . . . . . . . . . . . . . . . . . 314 [ECU] - 3429-Diesel particulate filter pressure sensor: Hoseline plausibility error . . . . . . . . . . . . . . . . . . 316 [ECU] - 3430-EGR inducement less severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 [ECU] - 3431-EGR Inducement most severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 [ECU] - 3433-Diesel particulate filter (DPF) inducement less severe derating level . . . . . . . . . . . . . . . . 319 [ECU] - 3434-Diesel particulate filter (DPF) inducement most severe derating level . . . . . . . . . . . . . . . 320 [ECU] - 3517-Ambient air temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 [ECU] - 3518-Ambient air temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 [ECU] - 3616-Torque limitation due to turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 [ECU] - 3648-Turbocharger: P2 pressure errors in PCR - pressure deviation too high . . . . . . . . . . . . . 326 [ECU] - 3650-Battery voltage: Source high for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 [ECU] - 3651-Battery voltage: Source low for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 [ECU] - 3652-CAN Bus: Bus off of CAN node A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 [ECU] - 3655-Torque limitation, engine protection: General report of the event of torque limitations . . 333 [ECU] - 3656-Torque limitation, engine protection: Torque limitation caused by particulate filter . . . . . 334 [ECU] - 3657-CAN Bus Received frames: Timeout error of CAN receive-frame CM1BC . . . . . . . . . . . 335 [ECU] - 3663-EGR command saturation over higher threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 [ECU] - 3664-EGR command saturation over lower threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 [ECU] - 3665-Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 [ECU] - 3666-Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 [ECU] - 3667-Open load error for power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 [ECU] - 3668-Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 [ECU] - 3669-Short circuit to battery on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 [ECU] - 3670-Short circuit to battery on Out2 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 [ECU] - 3671-Short circuit to ground on Out1 error for H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 [ECU] - 3672-Short circuit to ground on Out2 error for H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 [ECU] - 3673-Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 [ECU] - 3674-Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 [ECU] - 3675-Long time EGR valve drift at closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 [ECU] - 3676-EGR valve position sensor voltage source high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366 [ECU] - 3677-EGR valve position sensor voltage source low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 [ECU] - 3680-Injection cut off: Injection cut off demand for shut off coordinator . . . . . . . . . . . . . . . . . . . 372 84568014 22/03/2013

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[ECU] - 3688-Water sensor in the fuel filter: WIF sensor check is failed . . . . . . . . . . . . . . . . . . . . . . . . . . 373 [ECU] - 3689-DFC for faulty diagnostic data transmission or protocol error . . . . . . . . . . . . . . . . . . . . . . . 375 [ECU] - 3691-No load error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378 [ECU] - 3692-Over temperature error on ECU power stage for glow plug low voltage system . . . . . . . 380 [ECU] - 3693-Short circuit to battery error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383 [ECU] - 3694-Short circuit to ground error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 [ECU] - 3702-Injection control: Detection of failed engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389 [ECU] - 3703-Injection control: Check of minimum rail pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 [ECU] - 3704-Injector adjustment programming: Check of missing injector adjustment value programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391 [ECU] - 3705-Injector adjustment programming: Check of missing injector adjustment value programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392 [ECU] - 3706-Injector adjustment programming: Check of missing injector adjustment value programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393 [ECU] - 3707-Lambda sensor: Open circuit at the lambda sensor Nernst cell pin . . . . . . . . . . . . . . . . . . 394 [ECU] - 3708-Lambda sensor: Open circuit at the lambda sensor pump current pin - IP (lambda = 1 detection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397 [ECU] - 3709-Lambda sensor: Open circuit at the lambda sensor virtual ground pin . . . . . . . . . . . . . . . 400 [ECU] - 3712-Lambda sensor: SCG error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . . . . . . 403 [ECU] - 3713-Lambda sensor: Open load error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . 406 [ECU] - 3714-Lambda sensor: Fault code to indicate source high error for O2 calibration . . . . . . . . . . 408 [ECU] - 3715-Lambda sensor: Fault code to indicate source low error for O2 calibration . . . . . . . . . . . 411 [ECU] - 3716-Lambda sensor: O2 value above the max threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 [ECU] - 3720-Lambda sensor: Low battery voltage at the SPI chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416 [ECU] - 3722-Lambda sensor temperature Ri exceeds the maximum limit . . . . . . . . . . . . . . . . . . . . . . . 418 [ECU] - 3723-Lambda sensor temperature Ri is below the minimum limit . . . . . . . . . . . . . . . . . . . . . . . . 420 [ECU] - 3724-Lambda sensor: Short to battery at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422 [ECU] - 3725-Lambda sensor: Short to ground at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 [ECU] - 3727-Info: Low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426 [ECU] - 3728-Info: Too low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 [ECU] - 3735-Fuel metering unit: Over temperature of device driver of metering unit . . . . . . . . . . . . . . 428 [ECU] - 3736-Lambda sensor: O2 concentration is outside the predefined window during heater coupling detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430 [ECU] - 3737-Lambda sensor: Over temperature error of the LSU heater power stage . . . . . . . . . . . . . 431 [ECU] - 3738-Analog digital convertor (ADC): Diagnostic fault check to report multiple errors while checking the complete ROM-memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433 [ECU] - 3739-Power stages, injector: Loss of synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 [ECU] - 3740-Power stages, injector: DFC to set a torque limitation once an error is detected before MoCSOP's error reaction is set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435 [ECU] - 3741-Power stages, injector: Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 [ECU] - 3742-Power stages, injector: Too many SPI errors during MoCSOP execution . . . . . . . . . . . . 437 [ECU] - 3743-Power stages, injector: Diagnostic fault check to report the error in under voltage monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438 [ECU] - 3744-Power stages, injector: Diagnostic fault check to report the error in over voltage monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439

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[ECU] - 3745-Power stages, injector: Diagnostic fault check to report that WDA is not working correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 [ECU] - 3746-Power stages, injector: OS timeout in the shut off path test. Failure setting the alarm task period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 [ECU] - 3747-Power stages, injector: Diagnostic fault check to report that the positive test failed . . . . 442 [ECU] - 3748-Power stages, injector: Diagnostic fault check to report the timeout in the shut off path test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443 [ECU] - 3750-Injection control: Error in the plausibility of the injection energizing time . . . . . . . . . . . . . 444 [ECU] - 3751-Injection control: Error in the plausibility of the start of energizing angles . . . . . . . . . . . . 445 [ECU] - 3752-Zero Fuel Calibration (ZFC): Error in the plausibility of the energizing times of the zero fuel quantity calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446 [ECU] - 3753-Level 2 monitoring: Diagnostic fault check to report the error due to injection quantity correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 [ECU] - 3754-Level 2 monitoring: Diagnostic fault check to report the plausibility error in rail pressure monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448 [ECU] - 3755-Level 2 monitoring: Diagnostic fault check to report the error due to torque comparison 449 [ECU] - 3756-Level 2 monitoring: Diagnosis fault check to report the demand for normal mode due to an error in the post injection 2 quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 [ECU] - 3757-Level 2 monitoring: Diagnosis fault check to report the error to demand for an ICO due to an error in the post injection 2 shut off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 [ECU] - 3758-Level 2 monitoring: Diagnosis fault check to report the error to demand for an ICO due to an error in the post injection 3 efficiency factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452 [ECU] - 3759-Level 2 monitoring: Diagnosis of curr path limitation forced by ECU monitoring level 2 453 [ECU] - 3760-Level 2 monitoring: Diagnosis air path limitation due to a functional control unit monitoring forced by ECU monitoring level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 [ECU] - 3761-Level 2 monitoring: Diagnosis quantity path limitation due to a functional control unit monitoring (level 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455 [ECU] - 3762-Level 2 monitoring: Reported overvoltage of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456 [ECU] - 3763-Level 2 monitoring: Reported under voltage of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458 [ECU] - 3764-Main relay: Early opening defect of main relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 [ECU] - 3767-ECU internal: Diagnostic fault check to report 'WDA active' due to errors in query/response communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463 [ECU] - 3768-ECU internal: Diagnostic fault check to report 'ABE active' due to under voltage detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464 [ECU] - 3769-ECU internal: Diagnostic fault check to report 'ABE active' due to overvoltage detection 465 [ECU] - 3770-ECU internal: Diagnostic fault check to report 'WDA/ABE active' due to unknown reason 466 [ECU] - 3773-Turbocharger: Under boost detected in pressure charger regulator . . . . . . . . . . . . . . . . . 467 [ECU] - 3786-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469 [ECU] - 3787-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter very high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470 [ECU] - 3789-Regeneration duration exceeds maximum allowed duration . . . . . . . . . . . . . . . . . . . . . . . . 471 [ECU] - 3790-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472 [ECU] - 3794-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475 [ECU] - 3795-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478

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[ECU] - 3797-Diesel particulate filter pressure sensor: SRC high for PFlt differential pressure sensor 481 [ECU] - 3798-Diesel particulate filter pressure sensor: SRC low for PFlt differential pressure sensor 484 [ECU] - 3799-Pressure relief valve: Pressure relief valve is forced to open, perform pressure shock . 487 [ECU] - 3800-Pressure relief valve: Quantity balance check if a successful PRV opening is ensured 488 [ECU] - 3801-Turbine upstream pressure sensor: Source high for turbine upstream pressure sensor 489 [ECU] - 3802-Turbine upstream pressure sensor: Source low for turbine upstream pressure sensor . 492 [ECU] - 3803-ECU internal: Error on R2S2 module (low level chip driver for the power stage chips) . 495 [ECU] - 3808-Fuel metering unit: set point of metering unit not plausible . . . . . . . . . . . . . . . . . . . . . . . . . 496 [ECU] - 3810-Fuel pressure sensor: rail pressure raw value is intermittent . . . . . . . . . . . . . . . . . . . . . . . 497 [ECU] - 3811-ECU sensor supply monitor: ECU internal: Error sensor supplies 1 . . . . . . . . . . . . . . . . . 499 [ECU] - 3812-Physical range check high for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 [ECU] - 3813-Physical range check low for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501 [ECU] - 3814-ECU temperature sensor: SPI Error ECU temperature sensor (LM71) . . . . . . . . . . . . . . . 502 [ECU] - 3818-Open load error for power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503 [ECU] - 3819-Over current error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506 [ECU] - 3820-Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509 [ECU] - 3821-Short circuit to battery on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512 [ECU] - 3822-Short circuit to battery on Out2 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514 [ECU] - 3823-Short circuit to ground on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516 [ECU] - 3824-Short circuit to ground on Out2 error for H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519 [ECU] - 3826-Temperature dependent over current error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . 522 [ECU] - 3827-Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525 [ECU] - 3834-ECU Power stages: Throttle valve actuator power stage source high . . . . . . . . . . . . . . . 526 [ECU] - 3835-ECU Power stages: Throttle valve actuator power stage source low . . . . . . . . . . . . . . . . 528 [ECU] - 3838-Oxidation catalyst upstream temperature sensor short to high source . . . . . . . . . . . . . . . 530 [ECU] - 3839-Oxidation catalyst upstream temperature sensor short to low source . . . . . . . . . . . . . . . . 533 [ECU] - 3840-Diesel particulate filter upstream temperature sensor short to high source . . . . . . . . . . . 535 [ECU] - 3842-Turbine upstream temperature sensor: Source high for turbine upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538 [ECU] - 3843-Turbine upstream temperature sensor: Source low for turbine upstream temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541 [ECU] - 3844-Error state on comparing energizing time to maximum value injector 1 . . . . . . . . . . . . . . 544 [ECU] - 3845-Error state on comparing energizing time to maximum value injector 2 . . . . . . . . . . . . . . 545 [ECU] - 3846-Error state on comparing energizing time to maximum value injector 3 . . . . . . . . . . . . . . 546 [ECU] - 3847-Error state on comparing energizing time to maximum value injector 4 . . . . . . . . . . . . . . 547 [ECU] - 3848-Error state on comparing energizing time to minimum value injector 1 . . . . . . . . . . . . . . . 548 [ECU] - 3849-Error state on comparing energizing time to minimum value injector 2 . . . . . . . . . . . . . . . 549 [ECU] - 3850-Error state on comparing energizing time to minimum value injector 3 . . . . . . . . . . . . . . . 550 [ECU] - 3851-Error state on comparing energizing time to minimum value injector 4 . . . . . . . . . . . . . . . 551 [ECU] - 3852-Lambda (oxygen) sensor: The maximum allowed time for blow out is exceeded . . . . . . 552 [ECU] - 3870-Timeout for BC2EDC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553 [ECU] - 3899-Info: Engine temperature exceeded pre-warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555 [ECU] - 3900-Info: Engine temperature exceeded warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556

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[ECU] - 3906-Injector: Number of injections is limited by quantity balance of high pressure pump . . . 557 [ECU] - 3910-Fuel metering unit: Error check for loose contact between metering unit and ECU . . . . 558 [ECU] - 3915-Pressure Relief Valve: Averaged rail pressure is outside the expected range with open PRV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560 [ECU] - 3916-Pressure Relief Valve: Open time of PRV for wear out monitoring had exceeded maximum value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561 [ECU] - 3999-Unknown ECM SPN error code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562 [XCM (multi-function CM)] - 1002-Poor or no signal from radar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564 [XCM (multi-function CM)] - 1003-Speed sensor error NO SIGNAL FROM SPEED SENSOR . . . . . . . 567 [XCM (multi-function CM)] - 1005-speed sensor signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568 [XCM (multi-function CM)] - 1006-Slip Control Potentiometer Voltage Too Low . . . . . . . . . . . . . . . . . . . 569 [XCM (multi-function CM)] - 1007-Slip Control Potentiometer Voltage Too High . . . . . . . . . . . . . . . . . . . 571 [XCM (multi-function CM)] - 1009-Both external switches operated at the same time . . . . . . . . . . . . . . 573 [XCM (multi-function CM)] - 1010-Height Limit Control Potentiometer Voltage Too Low . . . . . . . . . . . . 575 [XCM (multi-function CM)] - 1011-Height Limit Control Potentiometer Voltage Too High . . . . . . . . . . . . 577 [XCM (multi-function CM)] - 1012-Drop Rate Control Potentiometer Voltage Too Low . . . . . . . . . . . . . . 579 [XCM (multi-function CM)] - 1013-Drop Rate Control Potentiometer Voltage Too High . . . . . . . . . . . . . 581 [XCM (multi-function CM)] - 1014-Right hand load sensing pin - signal too low . . . . . . . . . . . . . . . . . . . 583 [XCM (multi-function CM)] - 1015-Right hand load sensing pin - signal too high . . . . . . . . . . . . . . . . . . . 585 [XCM (multi-function CM)] - 1021-Draft Sensitivity Control Potentiometer Voltage Too Low . . . . . . . . . 587 [XCM (multi-function CM)] - 1022-Draft Sensitivity Control Potentiometer Voltage Too High . . . . . . . . 589 [XCM (multi-function CM)] - 1023-CONTROL PANEL DISCONNECTED . . . . . . . . . . . . . . . . . . . . . . . . . 591 [XCM (multi-function CM)] - 1025-Position Control Potentiometer Voltage Too Low . . . . . . . . . . . . . . . . 593 [XCM (multi-function CM)] - 1026-Position Control Potentiometer Voltage Too High . . . . . . . . . . . . . . . 595 [XCM (multi-function CM)] - 1027-Lift arm position sensing control voltage low (short or open circuit) 597 [XCM (multi-function CM)] - 1030-Signal Ground Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599 [XCM (multi-function CM)] - 1032-Draft Control Potentiometer Voltage Too High . . . . . . . . . . . . . . . . . . 601 [XCM (multi-function CM)] - 1033-Draft Control Potentiometer Voltage Too Low . . . . . . . . . . . . . . . . . . 603 [XCM (multi-function CM)] - 1049-Wheel speed sensor open or short circuit . . . . . . . . . . . . . . . . . . . . . . 605 [XCM (multi-function CM)] - 1053-5 volt reference shorted to +VE voltage . . . . . . . . . . . . . . . . . . . . . . . 607 [XCM (multi-function CM)] - 1054-CONTROLLER 5 VOLT REFERENCE SHORT TO GROUND . . . . 609 [XCM (multi-function CM)] - 1057-Module failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611 [XCM (multi-function CM)] - 1059-8 volt reference open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613 [XCM (multi-function CM)] - 1067-EDC hydraulic valve supply voltage too low . . . . . . . . . . . . . . . . . . . . 615 [XCM (multi-function CM)] - 1068-Height limit calibration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617 [XCM (multi-function CM)] - 2006-Radar no signal fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618 [XCM (multi-function CM)] - 2011-Clutch pedal potentiometer signal too low . . . . . . . . . . . . . . . . . . . . . . 621 [XCM (multi-function CM)] - 2012-Clutch pedal potentiometer signal too high . . . . . . . . . . . . . . . . . . . . . 624 [XCM (multi-function CM)] - 2014-Voltage from the gear neutral position switch is high . . . . . . . . . . . . 627 [XCM (multi-function CM)] - 2015-Voltage from the gear neutral position switch is low . . . . . . . . . . . . . 630 [XCM (multi-function CM)] - 2016-Voltage from the range position switch (R1) is high . . . . . . . . . . . . . 633 [XCM (multi-function CM)] - 2017-Voltage from the range position switch (R1) is low . . . . . . . . . . . . . . 636 [XCM (multi-function CM)] - 2018-Voltage from the range position switch (R2) is high . . . . . . . . . . . . . 639

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[XCM (multi-function CM)] - 2019-Voltage from the range position switch (R2) is low . . . . . . . . . . . . . . 642 [XCM (multi-function CM)] - 2021-drive line harness disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645 [XCM (multi-function CM)] - 2024-All clutches not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646 [XCM (multi-function CM)] - 2025-Over limit value , Engine speed (rpm) high . . . . . . . . . . . . . . . . . . . . . 647 [XCM (multi-function CM)] - 2026-Not calibrated , clutch D not calibrated . . . . . . . . . . . . . . . . . . . . . . . . 648 [XCM (multi-function CM)] - 2027-Not calibrated , Clutch C not calibrated . . . . . . . . . . . . . . . . . . . . . . . . 650 [XCM (multi-function CM)] - 2028-Not calibrated , Clutch B not calibrated . . . . . . . . . . . . . . . . . . . . . . . . 652 [XCM (multi-function CM)] - 2029-Not calibrated , Clutch A not calibrated . . . . . . . . . . . . . . . . . . . . . . . . 654 [XCM (multi-function CM)] - 2030-Unidentified failure , Critical code on transmission . . . . . . . . . . . . . . 656 [XCM (multi-function CM)] - 2033-Pressure on clutch A would not decrease . . . . . . . . . . . . . . . . . . . . . . 658 [XCM (multi-function CM)] - 2035-Wheel speed too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660 [XCM (multi-function CM)] - 2036-Engine speed (rpm) low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661 [XCM (multi-function CM)] - 2037-Clutch disconnect switch circuit open . . . . . . . . . . . . . . . . . . . . . . . . . 663 [XCM (multi-function CM)] - 2038-Clutch B solenoid valve short to +12 V . . . . . . . . . . . . . . . . . . . . . . . . 666 [XCM (multi-function CM)] - 2039-Clutch B solenoid valve open circuit or short to ground . . . . . . . . . . 668 [XCM (multi-function CM)] - 2040-Inconsistent gear lever status switches . . . . . . . . . . . . . . . . . . . . . . . . 669 [XCM (multi-function CM)] - 2041-Clutch A solenoid valve open circuit or short to ground . . . . . . . . . . 671 [XCM (multi-function CM)] - 2042-Clutch A solenoid valve short to +12 V . . . . . . . . . . . . . . . . . . . . . . . . 673 [XCM (multi-function CM)] - 2043-Pressure on clutch B would not decrease . . . . . . . . . . . . . . . . . . . . . . 675 [XCM (multi-function CM)] - 2047-Clutch disconnect switch set too high . . . . . . . . . . . . . . . . . . . . . . . . . 678 [XCM (multi-function CM)] - 2048-Clutch disconnect switch set too low . . . . . . . . . . . . . . . . . . . . . . . . . . 680 [XCM (multi-function CM)] - 2049-Wheel speed sensor voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . 683 [XCM (multi-function CM)] - 2051-Oil temperature sensor - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 685 [XCM (multi-function CM)] - 2053-5 Volt sensor supply too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 688 [XCM (multi-function CM)] - 2054-5 Volt sensor supply too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 690 [XCM (multi-function CM)] - 2055-Shuttle lever forward switch voltage high . . . . . . . . . . . . . . . . . . . . . . 692 [XCM (multi-function CM)] - 2056-Shuttle lever forward switch voltage low . . . . . . . . . . . . . . . . . . . . . . . 694 [XCM (multi-function CM)] - 2057-Shuttle lever reverse switch voltage high . . . . . . . . . . . . . . . . . . . . . . 696 [XCM (multi-function CM)] - 2058-Shuttle lever reverse switch voltage low . . . . . . . . . . . . . . . . . . . . . . . 698 [XCM (multi-function CM)] - 2059-Shuttle lever switches disagree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 [XCM (multi-function CM)] - 2065-Clutch C solenoid valve open circuit or short to ground . . . . . . . . . . 702 [XCM (multi-function CM)] - 2066-Clutch D solenoid valve open circuit or short to ground . . . . . . . . . . 704 [XCM (multi-function CM)] - 2067-Clutch D solenoid valve short to +12 V . . . . . . . . . . . . . . . . . . . . . . . . 706 [XCM (multi-function CM)] - 2068-Clutch C solenoid valve short to +12 V . . . . . . . . . . . . . . . . . . . . . . . . 708 [XCM (multi-function CM)] - 2069-Wheel speed sensor voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . 709 [XCM (multi-function CM)] - 2081-Clutch A safety pressure switch open circuit or short to ground . . . 711 [XCM (multi-function CM)] - 2082-Clutch A safety pressure switch short circuit . . . . . . . . . . . . . . . . . . . 714 [XCM (multi-function CM)] - 2083-Clutch B safety pressure switch open circuit or short to ground . . . 716 [XCM (multi-function CM)] - 2084-Clutch B safety pressure switch short circuit . . . . . . . . . . . . . . . . . . . 718 [XCM (multi-function CM)] - 2085-No supply to pressure switches for clutch A and B . . . . . . . . . . . . . . 720 [XCM (multi-function CM)] - 2090-Break in CAN communication between the ADIC and the XCM transmission control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722 [XCM (multi-function CM)] - 2092-Short circuit to + 12V from the clutch cut-out switch . . . . . . . . . . . . . 723

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[XCM (multi-function CM)] - 2093-Short circuit to +12VF to the gear lever switch feed signal . . . . . . . 725 [XCM (multi-function CM)] - 2094-Short circuit to ground to the gear lever switch feed signal . . . . . . . 727 [XCM (multi-function CM)] - 2095-Clutch cut-out button jammed closed . . . . . . . . . . . . . . . . . . . . . . . . . . 729 [XCM (multi-function CM)] - 2097-Short circuit to +12V to the discharge (dump) solenoid valve . . . . . 731 [XCM (multi-function CM)] - 2098-Short circuit to ground or circuit open to the discharge (dump) solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733 [XCM (multi-function CM)] - 2110-Shuttle lever neutral switch voltage too low . . . . . . . . . . . . . . . . . . . . 736 [XCM (multi-function CM)] - 2111-Shuttle lever neutral switch voltage too high . . . . . . . . . . . . . . . . . . . . 738 [XCM (multi-function CM)] - 2419-reactivity switch disagreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740 [XCM (multi-function CM)] - 2422-Multicontroller configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742 [XCM (multi-function CM)] - 2429-Creeper switch always on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743 [XCM (multi-function CM)] - 2430-Creeper unit status switch voltage too low . . . . . . . . . . . . . . . . . . . . . 745 [XCM (multi-function CM)] - 2431-Creeper unit status switch voltage too high . . . . . . . . . . . . . . . . . . . . 748 [XCM (multi-function CM)] - 2450-Configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751 [XCM (multi-function CM)] - 5007-PTO clutch solenoid valve short to + 12V . . . . . . . . . . . . . . . . . . . . . . 752 [XCM (multi-function CM)] - 5008-PTO clutch solenoid valve open circuit or short to ground . . . . . . . . 754 [XCM (multi-function CM)] - 5027-PTO speed sensor open circuit or short circuit to VBAT . . . . . . . . . . 756 [XCM (multi-function CM)] - 5034-Rear PTO fender switch - open circuit/short to ground . . . . . . . . . . . 758 [XCM (multi-function CM)] - 5037-Cab rear PTO switch jammed on (normally off) . . . . . . . . . . . . . . . . . 760 [XCM (multi-function CM)] - 5043-Rear PTO fender switch stuck on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762 [XCM (multi-function CM)] - 5044-PTO speed sensor short circuit to ground . . . . . . . . . . . . . . . . . . . . . . 765 [XCM (multi-function CM)] - 5045-Ground speed PTO switch open/short to GND . . . . . . . . . . . . . . . . . 767 [XCM (multi-function CM)] - 5046-Ground speed PTO switch short to 12V . . . . . . . . . . . . . . . . . . . . . . . 770 [XCM (multi-function CM)] - 5047-Ground speed PTO configuration error . . . . . . . . . . . . . . . . . . . . . . . . 772 [XCM (multi-function CM)] - 5098-Rear PTO fender switch option not enabled . . . . . . . . . . . . . . . . . . . . 773 [XCM (multi-function CM)] - 6023-Four-wheel drive clutch solenoid valve open circuit or short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 774 [XCM (multi-function CM)] - 7017-Differential lock solenoid valve open circuit or short to ground . . . . 776

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Electrical systems - FAULT CODES

1004-Wheel Speed Sensor Signal Too High 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. IIf no other error codes are displayed,continue to step 2 2. Check the wheel speed sensor. 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 ay 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

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 (N/W) and X-210 pin 20 wire 0.5 (N/W) 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 (N/W) and X-326 pin F wire 0.5 (B/Y) X-326 pin E wire 0.5 (N/W) and ground X-326 pin F wire 0.5 (B/Y) and ground X-326 pin H wire 0.5 (TQ) and X-326 pin F wire 0.5 (B/Y) 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: 84568014 22/03/2013

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Electrical systems - FAULT CODES

X-326 pin G wire 0.5 (G/B) and X-210 pin 18 wire 0.5 (G/B) 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 (B/Y) and X-326 pin G wire 0.5 (GB) X-326 pin F wire 0.5 (B/Y) and ground X-326 pin G wire 0.5 (GB) and ground X-326 pin H wire 0.5 (TQ) and X-326 pin F wire 0.5 (B/Y) 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 (B/Y) and F-009 (5A) wire 1.0 (B/Y) 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 (G/B) and X-210 pin 20 wire 0.5 (N/W) X-210 pin 18 wire 0.5 (G/B) and X-230 pin 6 wire 0.5 (TQ) X-210 pin 20 wire 0.5 (N/W) 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 (G/B) and pin 20 (N/W) 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 (N/W) and X-210 pin 20 wire 0.5 (N/W) X-326 pin G wire 0.5 (G/B) and X-210 pin 18 wire 0.5 (G/B) 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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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1017-Left Hand Load Sensing Pin Signal Too High 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 approximately 47, 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 approximately 47, 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 (B) and ground. X-331 pin 2 wire 1.0 (Y/G) and ground. X-331 pin 3 wire 1.0 (S/TQ) 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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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

1018-Both Load Sensing Pins Disconnected 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 (B) and X-200 pin 23 wire 1.0 (B). X-332 pin 2 wire 1.0 (S/G) and X-210 pin 9 wire 1.0 (S/G) X-332 pin 3 wire 1.0 (S/TQ) and X-210 pin 25 wire 1.0 (S/U) X-331 pin 1 wire 1.0 (B) and X-200 pin 23 wire 1.0 (B). X-331 pin 2 wire 1.0 (Y/G) and X-210 pin 10 wire 1.0 (Y/G) X-331 pin 3 wire 1.0 (S/TQ) and X-210 pin 25 wire 1.0 (S/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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Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

1019-Load Sensing Pin 8V Reference Voltage Too Low 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 approximately 79, 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 approximately 79, 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 (S/TQ) and ground X-332 pin 3 wire 1.0 (S/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 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 (S/TQ) and X-210 pin 25 wire 1.0 (S/U) X-332 pin 1 wire 0.5 (B) and X-200 pin 23 wire 1.0 (B) X-331 pin 3 wire 1.0 (S/TQ) and X-210 pin 25 wire 1.0 (S/U) X-331 pin 1 wire 1.0 (B) and X-200 pin 23 wire 1.0 (B). 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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Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

1020-Load Sensing Pin 8V Reference Voltage Too High 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 approximately 79, 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 approximately 79, 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-332 pin 3 wire 1.0 (S/TQ) and ground X-332 pin 2 wire 1.0 (S/G) and ground X-332 pin 1 wire 0.5 (B) and ground X-331 pin 3 wire 1.0 (S/TQ) and ground X-331 pin 2 wire 1.0 (Y/G) and ground X-331 pin 1 wire 1.0 (B) 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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Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

1024-Perform The Hydraulic Lift Calibration 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 Electronic module - H1 - Calibration procedures (55.640).

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Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

1028-Lift Arm Position Sensing Control Voltage Too High 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 79 to 6, 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/W) 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 (S/W) 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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Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

1029-Hydraulic Control Valve Disconnected 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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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1031-Chassis Harness Disconnected 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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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03) Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

1063-EDC Hydraulic Valve Lower Solenoid Open 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 to ground. A. Check between the connector: X-335 pin 1 wire 1.0 (G/W) 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 (G/Y) 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 (G/Y) and X-220 pin 5 wire 1.0 (G/Y) X-335 pin 1 wire 1.0 (G/W) and X-200 pin 12 wire 1.0 (G/W). 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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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1064-EDC Hydraulic Valve Raise Solenoid Open Circuit 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 (B/W) 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 (G/W) 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 (G/w) and X-220 pin 4 wire 1.0 (G/W) X-334 pin 1 wire 1.0 (B/W) and X-200 pin 5 wire 1.0 (B/W). 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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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1065-EDC Hydraulic Valve Lower Solenoid Short Circuit 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 (G/Y) 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 (G/W) 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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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1066-EDC Hydraulic Valve Raise Solenoid Short Circuit 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 (G/W) 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 (B/W) 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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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

2052-Oil Temperature Sensor - Short Circuit Context: Cause: Short to ground between the oil temperature sensor and the control unit ( XCM), the sensor is faulty, or the oil temperature is above 130 Â°C. Effects: It is presumed that the oil is hot. If the oil is cold, sluggish shifting and a higher than normal clutch pedal bite point will be indicated. Possible failure modes: 1. Oil temperature 2. Faulty connectors 3. Oil temperature sensor faulty 4. Wiring fault 5. Control unit ( XCM) fault Solution: 1. Check the transmission oil temperature sensor in H9, Channel 14. A. The value will change dependant on temperature, at 25 Â°C (77.0 Â°F) 52 is displayed; if the reading is incorrect, continue to step 2 B. If the values displayed are okay, while still in H9 channel 14, wiggle the harness, the transmission oil temperature sensor connector X-316, the connectors of the control unit ( XCM) X-200 and X-210 and the transmission -- cab main connector X-300 to check for an intermittent circuit. Channel 14 values will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the temperature sensor connector X-316, the connectors of the control unit ( XCM) X-200 and X-210 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 for a short circuit in the temperature sensor. A. Disconnect the connector X-316. Check the connector between: X-316 pin A and B If a short circuit is indicated, remove and replace the temperature sensor. B. If a short circuit is not indicated, continue to step 4 4. Check the temperature sensor for a short to ground. A. 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 5 5. Check for a short to ground. A. Check between the connector: X-316 pin B, wire 1.0 (U/R) 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 control unit ( XCM). 84568014 22/03/2013

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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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

3406-ECU Power stages: Over temperature error on the Turbocharger PWM output power stage 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-053. 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.

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Electrical systems - FAULT CODES

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 (B) 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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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 01 (55.100.DP-C.20.E.01) 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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Electrical systems - FAULT CODES

3699-EEPROM: Error in EEPROM block EEPData1, SD correction can not be calculated Context: The engine control unit (ECU) has detected the correction values, used in pressure rail regulation, are corrupted or inaccessible. Try to flash the ECU correctly with the proper data set. If the fault persists, replace the ECU.

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Electrical systems - FAULT CODES

3710-Lambda sensor: Fault to indicate dynamics of the sensor signal too small 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 (G) 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 X-943 pin 3, wire 314 (G) X-943 pin 1, wire 316 (O) X-943 pin 5, wire 318 (Y) X-943 pin 2, wire 317 (S) X-943 pin 6, wire 315 (N)

To X-937 pin 7, wire 314 (G) X-937 pin 64, wire 316 (O) X-937 pin 86, wire 318 (Y) X-937 pin 85, wire 317 (S) X-937 pin 63, wire 315 (N)

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Result Continuity Continuity Continuity Continuity Continuity

Electrical systems - FAULT CODES

Test Type Short Circuit

From To X-943 pin 4, wire 319 (G/W) X-943 pin 3, wire 314 (G) X-943 pin 1, wire 316 (O) X-943 pin 5, wire 318 (Y) X-943 pin 2, wire 317 (S) X-943 pin 6, wire 315 (N)

Result No continuity

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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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

3711-SCB error of the LSU Heater Power stage 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 (G) 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 (G) 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 (G). 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 (G) to pin 4, wire 319 (G/W). The resistance should be greater than 10.0 ÎŠ. A. If the resistance is below 10.0 ÎŠ, the damaged wiring is in the engine harness between connector X-943 pin 3, wire 314 (G) to pin 4, wire 319 (G/W). Locate and repair the damaged wiring harness.

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B. If the resistance is greater than 10.0 立, 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 (G) to connector X-937 pin 7, wire 314 (G). The resistance should be less than 10.0 立. A. If the resistance is greater than 10.0 立, the damaged wiring is in the engine harness between connector X-943 pin 3 and connector X-937 pin 7, wire 314 (G). Locate and repair the damaged wiring harness. B. If the resistance is less than 10.0 立, 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.

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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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3721-Lambda sensor: Fault check to indicate SPI chip error of lambda sensor Context: The engine control unit (ECU) has detected the initialization register value of the SPI chip is different from the value written into the chip in the previous cycle. The SPI chip internal to the ECU is defective. Replace the ECU. .

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Electrical systems - FAULT CODES

3766-Diesel particulate filter pressure sensor: Fault check for the pressure sensor plausibility Context: The exhaust differential pressure is measured between the intake and exhaust of the diesel particulate filter in the exhaust. This fault is a result of the differential pressure being inaccurate. The pressure value is above 2.5 kPa (0.4 psi). Check the differential pressure sensor hoses, and connections. If all the connections are good, and no damage is found. Replace the differential pressure sensor.

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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

3825-Short circuit over load error for H-bridge 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 (R/Y) and ECU connector X-939 pin 34, wire 407 (O/W). 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. (2) Disconnect the TVA valve connector X966.

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(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 ÎŠ. A. The resistance is greater than 20,000 ÎŠ. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 ÎŠ. 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3841-Diesel particulate filter upstream temperature sensor shorted to low source 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 (G/W) 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 (G/W) and connector X-937 pin 84, wire 322 (G/W). 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 (B/W) to connector X-937 pin 83, wire 320 (B/W). 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 (B/W) and connector X-937 pin 83, wire 320 (B/W). 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 (G/W) to connector X-461 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 (G/W) and connector X-937 pin 84, wire 322 (G/W). 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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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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5033-Rear PTO Cab Normally Closed Switch Open Circuit Context: Effects: PTO disabled. Possible failure modes: 1. Faulty connectors 2. Faulty PTO switch 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the PTO cab switch connector X-350 and the connector of the control unit ( XCM) 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 (S/U) 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 control unit ( XCM) X-240. Check between the connector: X-350 pin 3, wire 0.5 (S) and X-240 pin 23, wire 0.5 (S) 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 (S) 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 control unit ( XCM).

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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+ Context: Effects: PTO disabled. With the key ON and pressing the PTO fender switch(es) the transmission control unit ( XCM) signals a fault: Possible failure modes: 1. Faulty PTO fender switch(es) 2. Wiring fault 3. Control unit ( XCM) fault Solution: 1. 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 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 (R/G) and ground X-349 pin 3, wire 0.5 (O) 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 control unit ( XCM).

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Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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CH-HOT OIL WARNING: displayed above 100 degrees C Possible failure modes: 1. Transmission oil is very hot

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CL-COLD OIL WARNING: displayed below 20 degrees C Possible failure modes: 1. Transmission oil is very cold

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U17-Seat switch not activated 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 ch 26. 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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U18-Correct start up procedure not used Possible failure modes: 1. Operator has carried out the calibration incorrectly

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U19-Oil temperature < 10 Â°C, calibration is not possible 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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U20-Parking brake not applied NOTE: Use the H5 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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U21-ERPM is below 1250, 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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U22-ERPM is above 1350, reduce throttle Possible failure modes: 1. Operator has not set the correct engine speed

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U23-Shuttle lever is in neutral, shift lever to forward NOTE: Use the H5 switch diagnostics of the RW 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 control unit ( XCM) 3. 12 V Supply to the shuttle lever is open circuit

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U24-Incorrect range selected NOTE: Use the H5 switch diagnostics of the RW transmission control unit to detect if the switches ( R1 and R2) are connected. Possible failure modes: 1. Operator has not selected the correct range 2. The range switch ( R1 or R2) is faulty 3. The gear linkage is out of adjustment

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U25-Main gear lever is in neutral NOTE: Use the H5 switch diagnostics of the RW transmission control unit to detect if the gear neutral switch is connected. Possible failure modes: 1. Operator has not selected a gear 2. The gear neutral switch is faulty 3. The gear linkage is out of adjustment

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U26-Clutch pedal is not up, release clutch pedal NOTE: Use the H9 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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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

U36-Calibration value too high 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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U37-Calibration value too low Possible failure modes: 1. Engine speed dropped too soon 2. Clutch pressure is not being controlled properly 3. Engine speed adjusted whilst completing calibration

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14015-5V supply 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 approximately 5000 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 approximately 5000 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 of 5000 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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Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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14016-5V supply 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 approximately 5000 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 approximately 5000 mV, continue to step 3 3. Check for a short to ground. A. Disconnect the controller connector X-460. 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 of 5000 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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Wire harnesses - Electrical schematic frame 15 (55.100.DP-C.20.E.15)

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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 12V has been detected at the analog-digital instrument cluster ( ADIC) connector X-460 pin 17, wire 0.5 (U/Y) 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 (U/Y) 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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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

01 14 16 16

(55.100.DP-C.20.E.01) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.16)

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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 (U/Y) 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 (U/Y) 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 Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

01 14 16 16

(55.100.DP-C.20.E.01) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.16)

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14051-Fuel tank level sender open circuit or short to high voltage Control Module : ADIC Possible failure modes: 1. Faulty connectors 2. Fuel tank level sender faulty 3. Wiring fault 4. Faulty analog-digital instrument cluster ( ADIC) Solution: 1. Check the fuel tank level sender potentiometer in H9, channel 25. A. Remove the fuel level sender. 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 sender 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 sender operation. A. Disconnect the connector X-354. Check the connector: X-354 between pins 1 and 2 If the resistances indicated are not between 30 ÎŠ at full and 250 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 0.5 (N) and X-450 pin 2 wire 0.5 (N). X-354 pin 1, wire 1.0 (B) and X-450 pin 6 , wire 1.0 (B). 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 0.5 (N) 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 16 (55.100.DP-C.20.E.16) Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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14052-Fuel tank level sender short to ground Control Module : ADIC Possible failure modes: 1. Faulty connectors 2. Fuel tank level sender faulty 3. Wiring fault 4. Faulty analog-digital instrument cluster ( ADIC) Solution: 1. Check the fuel level sender potentiometer in H9, channel 25. A. Remove the fuel level sender. 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 sender 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 sender operation. A. Disconnect the connector X-354. Check the connector: X-354 between pins 1 and 2 If the resistances indicated are not between 30 ÎŠ at full and 250 ÎŠ at empty, remove and replace the sender. 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 0.5 (N) 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 16 (55.100.DP-C.20.E.16) Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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14058-Seat Switch Closed for 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 1660 mV, with the driver standing, the display will show a value of approximately 3330 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 (G) 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 16 (55.100.DP-C.20.E.16) Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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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 1660 mV, with the driver standing, the display will show a value of approximately 3330 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 (B) and X-450 pin 6 wire 0.5 (B). X-355 pin 2, wire 0.5 (G) and X-450 pin 1, wire 0.5 (G) 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 (G) 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 16 (55.100.DP-C.20.E.16) Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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14094-Seat switch signal short 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 1660, with the driver standing, the display will show a value of approximately 3330. 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 (G) 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). Wire harnesses - Component localisation (55.100.DP-C.40.B.20) Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16) Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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14100-Pneumatic brake pressure sensor detected but 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, in H3 configure the air brake. NOTE: To enter the HH MENU programs, refer to Electronic module - View HH MENU ACCESS (55.640).

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14107-Front hitch present but not configured Control Module : ADIC Cause: The front hitch option has not been configured. Solution: 1. Check that the front hitch option has been configured. A. Enter the HH MENU programs of the ADIC, in H3 configure the front hitch. NOTE: To enter the HH MENU programs, refer to Electronic module - View HH MENU ACCESS (55.640).

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14108-Rear PTO sensor present but not configured Control Module : ADIC Cause: The rear PTO speed sensor option has not been configured, the analog-digital instrument cluster ( ADIC) detects the sensor via the wire. Solution: 1. Check that the rear PTO sensor option has been configured. A. Enter the HH MENU programs of the ADIC, in H3 configure the rear PTO sensor. NOTE: To enter the HH MENU programs, refer to Electronic module - View HH MENU ACCESS (55.640).

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14109-EDC present but not configured Control Module : ADIC Cause: The EDC option has not been configured. Solution: 1. Check that the EDC option has been configured. A. Enter the HH MENU programs of the ADIC, in H3 configure the EDC. NOTE: To enter the HH MENU programs, refer to Electronic module - View HH MENU ACCESS (55.640).

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14200-Battery isolator switch closed to battery at Key ON for more than 30 seconds Control Module : ADIC 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 , the connector X-385 , 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, the connector X-385, 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 an open circuit. With the battery isolator switch In the reset position it should indicate a closed circuit. 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 + 12 V A. Turn the Ignition Key Switch ’ON’ and measure the voltage between the connector: X-197 pin 4, wire 0.5 (R) and ground If the indicated voltage is not approximately + 12 V, repair or replace the harness as required. B. If + 12 V is indicated, continue to step 5 5. Check for an open circuit. A. Turn Ignition Key Switch ‘OFF’. Disconnect the connector of the analog-digital instrument cluster ( ADIC) X-460. Check between the connector: X-197 pin 3, wire 0.5 (S/U) and X-460 pin 2, wire 0.5 (S/U) 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 circuit. 84568014 22/03/2013

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A. Check between the connectors X-197 pin 3, wire 0.5 (S/U) and X-197 pin 4, wire 0.5 (R) X-197 pin 3, wire 0.5 (S/U) and X-197 pin 5, wire 0.5 (R) 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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Wire Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

01 02 16 16

(55.100.DP-C.20.E.01) (55.100.DP-C.20.E.02) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.16)

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14900-Control unit (XCM) disconnected Control Module : ADIC Possible failure modes: 1. Faulty connectors 2. Wiring fault 3. Control unit ( XCM) fault Solution: 1. Check the connector of the instrument cluster ( ADIC) X-450 and the connectors of the control unit ( XCM) 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 0.5 (O/B) and ground X-200 pin 14, wire 0.5 (U/W) and ground X-200 pin 20, wire 0.5 (B/Y) and ground X-240 pin 34, wire 0.5 (S/U) 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-200 pin 19, wire 1.0 (B) and ground X-200 pin 25, wire 1.0 (B) and ground X-200 pin 26, wire 1.0 (B) and ground X-220 pin 21, wire 1.0 (B) and ground X-220 pin 26, wire 1.0 (B) 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-200 ( CAN_H) pin 15, wire 0.75 (Y) and X-450 ( CAN_H) pin 3, wire 0.75 (Y) X-200 ( CAN_L) pin 16, wire 0.75 (G) and X-450 ( CAN_L) pin 4, wire 0.75 (G) 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 ( XCM).

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Wire Wire Wire Wire Wire Wire

harnesses harnesses harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical Electrical Electrical

schematic schematic schematic schematic schematic schematic

frame frame frame frame frame frame

03 (55.100.DP-C.20.E.03) 04 (55.100.DP-C.20.E.04) 11 (55.100.DP-C.20.E.11) 14 (55.100.DP-C.20.E.14) 16 (55.100.DP-C.20.E.16) 16 (55.100.DP-C.20.E.16)

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14901-Engine controller missing Control Module : ADIC 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 (Y) and X-450 ( CAN_H) pin 3, wire 0.75 (Y) X-937 ( CAN_H) pin 46, wire 0.75 (Y) and X-450 ( CAN_H) pin 3, wire 0.75 (Y) X-937 ( CAN_L) pin 25, wire 0.75 (G) and X-450 ( CAN_L) pin 4, wire 0.75 (G) X-937 ( CAN_L) pin 47, wire 0.75 (G) and X-450 ( CAN_L) pin 4, wire 0.75 (G) 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 harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical Electrical

schematic schematic schematic schematic schematic

frame frame frame frame frame

01 (55.100.DP-C.20.E.01) 11 (55.100.DP-C.20.E.11) 16 (55.100.DP-C.20.E.16) 16 (55.100.DP-C.20.E.16) 17 (55.100.DP-C.20.E.17)

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3001-Foot throttle sensor - signal not plausible 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: 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 500 - 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 84 (O) 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 (B) and ground X-321 pin 8, wire 75 (B) 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 (W/B) and X-450 pin 5, wire 34 (W/B) X-321 pin 6, wire 225 (W) and X-450 pin 7, ,wire 225 (W) 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: 84568014 22/03/2013

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X-321 pin 2, wire 34 (W/B) and ground X-321 pin 6, wire 225 (W) 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 (W/B) and ground X-321 pin 6, wire 225 (W) 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 (W/B) and X-321 pin 6, wire 225 (W) 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 15 (55.100.DP-C.20.E.15) Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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3002-Foot throttle sensor - signal above range maximum 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: 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 500 - 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 (B) 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 (W/B) and X-321 pin 2, wire 34 (W/B). 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 (W/B) 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 15 (55.100.DP-C.20.E.15)

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3003-Foot throttle sensor - signal below range minimum 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: 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 500 - 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 (B) 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 (W/B) and X-321 pin 2, wire 34 (W/B). 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 (W/B) 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 15 (55.100.DP-C.20.E.15)

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3126-Hand throttle - channel 1 signal above range max Control Module : ADIC 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 500 - 4500 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 (B) 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 (R). 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 (R) 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 15 (55.100.DP-C.20.E.15)

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3127-Hand throttle - channel 1 signal below range min 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. 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 500 - 4500 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 8 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 (B) 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 (R). 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 (R) 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 15 (55.100.DP-C.20.E.15)

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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’ (one internal ram), for 63 l/min (16.6 US gpm) and 80 l/min (21.1 US gpm) pumps. ‘A r2’ (one internal ram and two external ram’s), for 63 l/min (16.6 US gpm) and 80 l/min (21.1 US gpm) pumps. ‘b r0’ (one internal ram), only for 63 l/min (16.6 US gpm) pumps. ’b r2’ (one internal ram and two external ram’s), only for 63 l/min (16.6 US gpm) pumps.

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3006-Coolant temperature signal - signal not plausible (compared with engine oil temperature) 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 temp sensor signal to the ECU is either erratic or intermittent. 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 sor connector X-969 pin 1 X-939 (S/R) Coolant temperature sen- ECU sor connector X-969 pin 2 X-939, (S/TQ) ECU engine connector ECU X-939 pin 57, wire 421 X-939 (S/R) (S/TQ)

Expected Results engine connector Approx. 0 - 0.10 ohms pin 57, wire 421 engine connector Approx. 0 - 0.10 ohms pin 58, wire 422 engine connector Open Circuit pin 58, wire 422

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A. If continuity/short tests are successful, continue with step 4. 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 18 (55.100.DP-C.20.E.18)

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3007-Coolant temperature sensor - signal above range maximum 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 Approximately. 5 volts Coolant temperature sensor connector X-969 pin 2 (-)

Test Type 1. Continuity

2. Continuity

3. Short Circuit

Expected Results engine connector Approx. 0 - 0.10 ohms pin 57, wire 421 engine connector Approx. 0 - 0.10 ohms pin 58, wire 422 engine connector Open Circuit pin 58, wire 422

A. If continuity/short tests are successful, continue with step 4.

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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

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3008-Coolant temperature signal - signal below range minimum 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 (S/R) 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 15, wire 421 (S/R) 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-969 pin 58, wire 422 (S/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 18 (55.100.DP-C.20.E.18)

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3010-Boost temperature sensor - signal above range maximum 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. Test Type 1. Continuity 2. Continuity

From: X-961 pin 1 X-961 pin 2

To: Expected Results X-939 pin 25, wire 403 (O) Approx. 0 - 0.10 ohms X-939 pin 55, wire 420 Approx. 0 - 0.10 ohms (S/G)

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3. Continuity

X-961 pin 3

X-939 pin 10, wire 395 (G/B) pin 4 X-939 pin 40, wire 412 R/B) pin 55, wire 420 X-939 pin 25, wire 403 (O), pin 10, wire 395 (G/B), pin 40, wire 412 R/B) pin 25 X-939 pin 10, wire 395 (G/B), pin 40, wire 412 R/B) pin 40 X-939 pin 10, wire 395 (G/B)

Approx. 0 - 0.10 ohms

4. Continuity 5. Shorts

X-961 X-939 (S/G)

Approx. 0 - 0.10 ohms Open Circuit

6. Shorts

X-939

7. Shorts

X-939

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) 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)

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 214 ohms 186 ohms 162 ohms 142 ohms 125 ohms 110 ohms 97 ohms 84568014 22/03/2013

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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 207 - 220 ohms 180 - 192 ohms 157 - 167 ohms 138 - 147 ohms 121 - 129 ohms 106 - 113 ohms 93 - 100 ohms

Electrical systems - FAULT CODES

Temperature 130 Â°C (266 Â°F)

Resistance Nominal Value 85 ohms

Resistance Min/Max. Range 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 wire 745 (R/B), Ground (engine block) pin 3 wire 744 (R/Y), pin 5 wire 4 (R/Y), pin 54 wire 341 (O) X-937 pin 2 wire 311(B), pin Ground (engine block) 4 wire 312 (B), pin 6 wire 313 (B)

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 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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3011-Boost temperature sensor - signal below range minimum 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. Test Type 1. Continuity 2. Continuity

From: X-961 pin 1 X-961 pin 2

To: Expected Results X-939 pin 25, wire 403 (O) Approx. 0 - 0.10 ohms X-939 pin 55, wire 420 Approx. 0 - 0.10 ohms (S/G)

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3. Continuity

X-961 pin 3

Approx. 0 - 0.10 ohms

4. Continuity 5. Shorts

X-961 X-939 (S/G)

Approx. 0 - 0.10 ohms Open Circuit

6. Shorts

X-939

7. Shorts

X-939

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) 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)

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Temperature 130 Â°C (266 Â°F)

Resistance Nominal Value 85 ohms

Resistance Min/Max. Range 83 - 88 ohms

2. Continuity

Expected Results Approx. 12 volts

Approx. 0 - 0.10 ohms

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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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3015-Fuel temperature sensor - signal above range maximum 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 18 (55.100.DP-C.20.E.18)

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3016-Fuel temperature sensor - signal below range minimum 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 Approx. 0 - 0.10 ohms (TQ/W) X-939 pin 23, wire Approx. 0 - 0.10 ohms 401(N/W)

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3. Short Circuit

X-939 pin 38, wire 410 X-939 pin 10, wire 395 Open Circuit (TQ/W) (G/B)

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

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 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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3019-Boost pressure sensor - signal above range maximum 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. Test Type 1. Continuity 2. Continuity

From: X-961 pin 1 X-961 pin 2

To: Expected Results X-939 pin 25, wire 403 (O) Approx. 0 - 0.10 ohms X-939 pin 55, wire 420 Approx. 0 - 0.10 ohms (S/G)

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3. Continuity

X-961 pin 3

Approx. 0 - 0.10 ohms

4. Continuity 5. Shorts

X-961 X-939 (S/G)

Approx. 0 - 0.10 ohms Open Circuit

6. Shorts

X-939

7. Shorts

X-939

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

Expected Results Approx. 12 volts

Approx. 0 - 0.10 ohms

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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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3024-Atmospheric pressure sensor - signal above range maximum 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-Atmospheric pressure sensor - signal below range minimum 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-Oil pressure sensor: Defect fault check for plausibility from digital sensor 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 (B/W) 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. 84568014 22/03/2013

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(2) Disconnect the oil pressure switch connector X-959. (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 18 (55.100.DP-C.20.E.18)

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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 (G) 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 (G). 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 (G). 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 (G).. 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 (R/B) 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 (R/B). 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 (R/B). 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 (G) 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3051-Battery voltage to ECU - 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. Cause: Possible failure modes: 1. External power supply connected 2. Faulty charging system 3. 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 power supply has not been connected to an external power supply. A. If an external power supply is connected to the machine, disconnect and test the system for normal operation. B. If an external power supply is not connected to the machine, 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, download the correct level of software. If the fault re-occurs, remove and replace the engine controller.

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3052-Battery voltage to ECU - 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 F51, F52 and F57. 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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Wire harnesses - Electrical schematic frame 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3059-ECU main relay: Stuck main relay error 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 K200 . 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 K200. A. Remove the ECU main relay K200 and check the operation of the relay. If the relay does not operate correctly, replace the ECU main relay K200. 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 K200. Check between connector X-937 pin 28, wire 743 (B/W). 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 (R/B) 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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Wire harnesses - Electrical schematic frame 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3063-Cylinder1 - injector cable short circuit (high side to ground) 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3071-Cylinder 3 - injector cable short circuit (high side to ground) 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-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 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-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 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-952 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-952 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. Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3079-Cylinder 2 - injector cable short circuit (high side to ground) 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 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 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-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 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-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 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-954 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-954 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. Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3083-Cylinder 4 - injector cable short circuit (high side to ground) 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-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 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-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 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-953 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-953 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. Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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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: 84568014 22/03/2013

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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 (W) Crankshaft speed sensor ECU engine harness conconnector X-965 pin: 2 nector X-939 pin: 59, wire 423 (R) ECU engine harness con- ECU engine harness connector X-939 pin: 44, wire nector X-939 pin: 59, wire 415 (W) 423 (R)

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

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 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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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 (R). 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 (R). 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. 84568014 22/03/2013

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Test Type 1. Voltage

2. Continuity

Expected Results Approx. 12 volts (DC)

Approx. 0 - 0.10 ohms

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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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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 (N/B). 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 18 (55.100.DP-C.20.E.18)

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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 84568014 22/03/2013

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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 (N/B). 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 18 (55.100.DP-C.20.E.18)

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3093-Offset between camshaft and crankshaft - outside boundaries 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 18 (55.100.DP-C.20.E.18)

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3096-ECM Busoff on vehicle CAN 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 (Y) and X-450 ( CAN_H) pin 3, wire 0.75 (Y) X-937 ( CAN_H) pin 46, wire 0.75 (Y) and X-450 ( CAN_H) pin 3, wire 0.75 (Y) X-937 ( CAN_L) pin 25, wire 0.75 (G) and X-450 ( CAN_L) pin 4, wire 0.75 (G) X-937 ( CAN_L) pin 47, wire 0.75 (G) and X-450 ( CAN_L) pin 4, wire 0.75 (G) 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 harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical Electrical

schematic schematic schematic schematic schematic

frame frame frame frame frame

01 (55.100.DP-C.20.E.01) 11 (55.100.DP-C.20.E.11) 16 (55.100.DP-C.20.E.16) 16 (55.100.DP-C.20.E.16) 17 (55.100.DP-C.20.E.17)

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3102-Rail pressure sensor CP3 - signal below range min 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 (R/G) 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 (G/W) 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 18 (55.100.DP-C.20.E.18)

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3104-Rail pressure 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 18 (55.100.DP-C.20.E.18)

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3105-Rail pressure relief valve - pressure shock requested Control Module : ECU Context: The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too high and the Pressure Relief Valve (PRV) did not open. Normally the fuel pressure in the rail is regulated by the metering unit of the high pressure pump. However, if this component is malfunctioning the rail pressure can rise to critical levels. For this reason the common rail has a Pressure Relief Valve (PRV) which is a mechanical safety valve (no electrical connectors) that opens at a certain pressure level. An opening of the PRV is detected by evaluating the gradient of the rail pressure (calculated by the ECU). If the PRV does not open on its own after exceeding the pressure threshold it can also be forced open by a so-called 'kickoff' or pressure shock when the metering valve of the high pressure fuel pump is set to maximum possible quantity. If the pressure shock (kickoff) does not immediately open the PRV, this error will occur. This fault will only be cleared after an ECU reset. Possible failure modes: 1. Faulty ECU, improper data set. 2. Faulty PRV, mechanical valve does not function. Solution: 1. Use the EST to flash the ECU with the appropriate data set. A. If the error reoccurs, replace the PRV. B. If the error does not reoccur, return the machine to service.

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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-Fuel metering unit - 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 (S/W) 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 18 (55.100.DP-C.20.E.18)

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3108-Fuel metering unit - 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 (S/W) 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 18 (55.100.DP-C.20.E.18)

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3112-Rail pressure sensor CP3 - signal above range maximum 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 (R/G) 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 (R/G), 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 (G/W) 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 18 (55.100.DP-C.20.E.18)

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3137-Metering unit - open load 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 (N/G) to pin 60, wire 424 (S/W). 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 (N/G). 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 (S/W). 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 18 (55.100.DP-C.20.E.18)

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3139-Metering unit signal range check - 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 4, wire 413 (R/G) 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3140-Metering unit signal range check - 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 4, wire 413 (R/G) 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3141-Fuel flow setpoint too low - fuel metering unit: leakage is detected based on fuel quantity balance Control Module : ECU Context: The Fuel Rail pressure control is executed with 2 device, 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 system is in mode "only metering unit" (i.e. PCV fully closed) the desired fuel flow is adjusted by feed back control for reaching the desired fuel pressure. If this required fuel flow exceeds a maximal expected fuel flow by more than a fuel flow dependant value, leakage in the system must be assumed The engine control unit (ECU) has determined the high pressure pump delivery quantity exceeds the maximal expected fuel flow by more than a fuel flow dependant limit This error can be the result of an external leakage in the high pressure or low pressure system, a low fuel rail pressure sensor signal value, an internal injector leak, a high pressure pump low supply efficiency or a restriction within the fuel supply.

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3146-Water sensor in the fuel filter : Water in fuel level sensor defect detection 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 (O) 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 (B) 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 (Y) and X-937 pin 30, wire 347 (Y). 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 (Y) 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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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3157-Engine control unit (ECU) not detected on the CANbus or the engine dataset registration information was not available from the engine within the time required 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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Wire harnesses - Electrical schematic frame 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3158-Invalid ECM checksum (the engine dataset does not match the dataset registered for this machine. Register the new dataset if the dataset has just been updated) Control Module : ECU Cause: The code 3158 can appear after downloading software to the Engine Controller and completing the dataset registration, if the engine was not allowed to run for at least five minutes before keying off. 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. Possible failure modes: 1. Engine controller does not have the valid data set installed. 2. The new engine data set has not been registered on the machine. 3. The engine was not allowed to run for at least five minutes after completing a dataset registration before keying off. Solution: 1. 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;? If the code 3158 appears or the message to register the dataset appears on the EST and the registration procedure has already been completed, it should not need to be completed again. Just start the engine and let it run for five minutes. Once the machine runs for five minutes, the fault can go 'inactive' or 'non present'. Once this occurs, the fault code can be cleared and should not appear again. If the fault does appear again, run the machine an additional five minutes to ensure the fault does not occur again.

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Electrical systems - FAULT CODES

3166-Fuel filter 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 (G) 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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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3167-Fuel filter 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 (G) and ground X-110 pin R3_86, wire 1243 (N) 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 17 (55.100.DP-C.20.E.17)

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3168-Fuel filter heater relay - no load 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 (G) and X-110 pin R3_85, wire 1248 (B/Y) X-110 pin R3_86, wire 1243 (N) and X-110 pin 35A, wire 712 (N) 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 17 (55.100.DP-C.20.E.17)

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3169-Fuel filter 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 (G) and X-110 pin R3_85, wire 1248 (B/Y) X-110 pin R3_86, wire 1243 (N) and X-110 pin 35A, wire 712 (N) . 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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Wire harnesses - Electrical schematic frame 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3176-Fuel metering unit: Set point of metering unit in overrun mode not plausible Control Module : ECU 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. High pressure system leakage is checked at overrun. If the engine control unit (ECU) detects the high pressure pump delivery quantity in overrun exceeds the threshold value based on pressure, 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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3177-Engine overspeed detected Control Module : ECU Context: The Engine Control Unit (ECU) has detected an engine over-speed condition. An engine over-speed can occur both during certain engine operating conditions without any defect in a component, for example downhill driving, or as a result of, for example another ECU error. This error is for information purposes and is initiated by engine speed in excess of 3100 RPM and is reset once the engine speed is below the threshold. Though this error by itself does not require any action, the over-speed state can cause an injection shutoff request within the ECU. If this error reoccurs frequently, check driving conditions of the vehicle, engine speed acquisition and injection system for quantity set-point and actual value during fault recognition, check also for other ECU errors.

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3179-Timeout of CAN message BC2EDC2 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 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

13 14 16 17

(55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.17)

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3180-Timeout of CAN message VCM2EDC 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 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

13 14 16 17

(55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.17)

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3188-Injector cylinder 1 warning - open load 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/W) and pin 32, wire 432 (W/O). 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3192-Injector cylinder 2 warning - open load 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 (Y/B) and pin 2, wire 428 (TQ/G). 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-954 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-954. 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3196-Injector cylinder 3 warning - open load 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 (W) and pin 1, wire 427 (TQ/B). 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-952 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-952 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 18 (55.100.DP-C.20.E.18)

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3200-Injector cylinder 4 warning - open load 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/Y) and pin 48, wire 434 (Y/R). 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-953. 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-953. 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 18 (55.100.DP-C.20.E.18)

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3210-Bank 1 - general 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/W) to pin 32, wire 432 (W/O) 2. Pin 46, wire 433 (Y/B) to pin 2, wire 428 (TQ/G) 3. Pin 31, wire 431 (W) to pin 1, wire 427 (TQ/B) 4. Pin 17, wire 430 (TQ/Y) to pin 48, wire 434 (Y/R) 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. 84568014 22/03/2013

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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-954 if recorded pin in Step 3 was pin 2 3. Cylinder #3 injector at connector X-952 if recorded pin in Step 3 was pin 1 4. Cylinder #4 injector at connector X-953 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-954 (if recorded pin in Step 3 was pin 2), or connector X-952 (if recorded pin in Step 3 was pin 1), or connector X-953 (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-954, if recorded pins in Step 2 were pins 2 and 46 3. Cylinder #3 injector at connector X-952, if recorded pins in Step 2 were pins 1 and 31 4. Cylinder #4 injector at connector X-953, 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-954, or X-952, or X-953 and connector X-953 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 18 (55.100.DP-C.20.E.18)

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3218-Bank 2 - general 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/W) to pin 32, wire 432 (W/O) 2. Pin 46, wire 433 (Y/B) to pin 2, wire 428 (TQ/G) 3. Pin 31, wire 431 (W) to pin 1, wire 427 (TQ/B) 4. Pin 17, wire 430 (TQ/Y) to pin 48, wire 434 (Y/R) 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. 84568014 22/03/2013

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3230-Injection processor (CY33X) error - SPI communication failure Control Module : ECU Context: The engine control unit (ECU) has sensed a problem with the internal supply voltage for injectors, the fault path for errors in the power stage component of the unit injection system. The power stage monitors itself and reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If the power stage component On Time-out is present for at least one cylinder for longer than 3 camshaft revolutions , this error will occur. As a result of this error an individual cylinder or bank is shut off. This shut off is currently applied to be permanent without a healing possibility by switching on the component to see if the defect is still present. With either an irreversible or reversible shut off of the engine being executed. The reason for this failure is a defective ECU. If the fault doesn't reset or reoccurs, replace the ECU.

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3235-Number of injections limited - by charge balance Control Module : ECU Context: The number of injections is greater than normal injections released for current engine speed. This fault will correct when the number of injections are in range with engine speed. To correct this fault, try re-flashing the software. If that does not correct the fault, replace the ECU.

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3236-Number of injections limited - by quantity balance Control Module : ECU Context: The number of injections is greater than normal injections released for current engine speed. This fault will correct when the number of injections are in range with engine speed. To correct this fault, try re-flashing the software. If that does not correct the fault, replace the ECU.

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3237-Number of injections limited - by software Control Module : ECU Context: This fault has occurred because the desired number of injections is greater than maximum number of injections per cycle, depending on battery voltage and power requirements for energizing. Check battery voltage, and check power supply to the ECU. If battery voltage is low, charge battery and recheck. If battery does not hold a charge, replace the battery. If the power supply to the ECU is insufficient, check for other faults present. Resolve those faults. If the battery and power supply to the ECU are okay, replace the ECU.

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3238-ECU power stages: Errors of the power failure detection of CY320 Control Module : ECU Context: The hardware encapsulation of CY320 performs a diagnostic of the sensor supplies and monitors the communication between processor and voltage supply device CY320. The engine control unit (ECU) has detected communication disturbances between the processor and CY320 (data incorrect or a data transfer is not possible). This error is caused by an internal defect of the ECU. If failure remains present, replace the ECU.

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3239-Engine controller EEPROM - read operation failure Control Module : ECU Context: The engine control unit (ECU) has detected an error during the last EEPROM read operation. The hardware encapsulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found with at least three data blocks. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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3240-Engine controller EEPROM - write operation failure Control Module : ECU Context: The engine control unit (ECU) has detected an error during the last EEPROM write operation. The hardware encapsulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found with one memory block not being able to be written to more than three times. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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3241-Engine controller EEPROM - read/write error Control Module : ECU Context: The engine control unit (ECU) has detected the calibrated parameters for the baud rate cannot be read from the EEPROM. The hardware encapsulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found or not found. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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3242-ECU internal: Visibility of software resets in DSM Control Module : ECU Context: The engine control unit (ECU) has detected that a software internal failure occurred which lead to a software reset. This reset caused a failure which is only visible for approved diagnostic equipment. This error can be the result of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error occurs repeatedly, reprogram the ECU and if the error remains, replace the ECU.

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3243-ECU internal: Visibility of software resets in DSM Control Module : ECU Context: The engine control unit (ECU) has detected that a software internal failure occurred which lead to a software reset. This reset caused a failure which is only visible for approved diagnostic equipment. This error can be the result of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error occurs repeatedly, reprogram the ECU and if the error remains, replace the ECU.

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3244-ECU recovery (visible) - recovery occurred Control Module : ECU Context: The engine control unit (ECU) has detected, during system start up, a hardware or configuration problem. This triggers an ECU recovery (reset of the CPU - Central Processing Unit) that is visible in the error memory. During a fresh ECU start up different hardware tests are performed. If the error remains present even after reset, the software remains in the boot-block and the driving software is not processed. If three recoveries are triggered within 4 seconds an irreversible shut off of the system is carried out and the ECU is classified as permanently defective. In this case no error entry is possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed to start up, one of three recovery errors becomes active depending on the visibility of the recovery. This error can be the result of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error occurs repeatedly, reprogram the ECU and if the error remains, replace the ECU.

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Electrical systems - FAULT CODES

3245-ECM processor - watchdog not plausible Control Module : ECU Context: The engine control unit (ECU) has detected an internal (SPI Bus) communication failure. The central processing unit (CPU) and monitoring module (watchdog) contained with in the ECU, communicate with each other via the SPI bus. Both devices mutually monitor each other for correct functioning. If, however, the SPI communication between them fails this monitoring is impaired and an error counter is incremented. If the error counters exceeds the limit, this fault is activated. Communication status is checked autonomously by the SPI driver component every 80 ms and reports a detected error to the ECU. This error initiates ECU recovery (reset). If the ECU functions correctly after recovery, the SPI error is temporary and can be ignored and deleted from fault memory. If the SPI error is permanent and the ECU does not leave boot-block, the ECU needs to be replaced.

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Electrical systems - FAULT CODES

3252-Controller watchdog - SPI communication failure Control Module : ECU Context: The engine control unit (ECU) has detected an internal (SPI Bus) communication failure. The central processing unit (CPU) and monitoring module (watchdog) contained with in the ECU, communicate with each other via the SPI bus. Both devices mutually monitor each other for correct functioning. If, however, the SPI communication between them fails this monitoring is impaired and an error counter is incremented. If the error counter exceeds 0 over 80 ms and there is no active shut-off path test, this fault is activated. Communication status is checked autonomously by the SPI driver component every 80 ms and reports a detected error to the ECU. This error initiates ECU recovery (reset). If the ECU functions correctly after recovery, the SPI error is temporary and can be ignored and deleted from fault memory. If the SPI error is permanent and the ECU does not leave boot-block, the ECU needs to be replaced.

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Electrical systems - FAULT CODES

3253-Analog digital converter (ADC) : Diagnostic fault check to report the error in voltage ratio in ADC monitoring Control Module : ECU Context: The analog Digital Converter (ADC) of the engine control unit (ECU) is monitored for plausibility using redundantly read input (accelerator pedal) and test voltage inputs. If the ECU detects the ratio between 3.3 V and 5.0 V supply converted is not in range, this fault will occur. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3255-Analog digital converter (ADC) : Diagnostic fault check to report the ADC test error Control Module : ECU Context: The analog Digital Converter (ADC) of the engine control unit (ECU) is monitored for plausibility using redundantly read input (accelerator pedal) and test voltage inputs. A fixed test input voltage is cyclically converted by the ADC, its value should be in range between 4.73 - 4.83 V, if not a counter is increased. If the ECU detects the counter exceeds 15.00 , this fault will occur. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3256-Analog Digital Converter (ADC) : Diagnostic fault check to report the NTP error in ADC monitoring Control Module : ECU Context: The analog Digital Converter (ADC) of the engine control unit (ECU) is monitored for plausibility using redundantly read input (accelerator pedal) and test voltage inputs. If the ECU detects an error in the check with the no-load test pulse operation (NTP), this fault will occur. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3265-Overrun monitoring - injection time too long Control Module : ECU Context: The engine control unit (ECU) has detected that injection time is too long. The sum of all torque-forming energizing times of an individual cylinder exceeds the limit, calculated from the map (depending on the engine speed and the time since the overrun monitoring is active) for more than 100 test events. When the engine is in overrun operation the monitoring becomes active and the current injection energizing time is compared with a maximum permissible time limit. If the limit is exceeded an ECU recovery (reset ) is triggered and if the error reoccurs in the same driving cycle, the torque-determining power stages are irreversibly shut off. The basic idea is that the operator reacts to an unintentional torque increase, caused by a malfunction of the ECU, by releasing the accelerator pedal (reducing engine speed) which causes the engine to enter the overrun operation mode. Overrun monitoring is only released if various conditions are met, such as no accelerator pedal activation, no activated cruise control, no intervention of the vehicle dynamic control or gearbox control is present, etc. This failure could be the result of electronic disturbances, a requested torque increase via tester, the wrong application of injection relevant parameters, or a defective ECU. If this failure persists, the ECU may need to be replaced.

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Electrical systems - FAULT CODES

3266-Engine speed : Diagnostic fault check to report the engine speed error Control Module : ECU Context: A redundant check for engine speed is performed for function monitoring at software level 2. Monitoring in the engine control unit (ECU) takes place in 3 levels: Level 1: Functions level (engine control, component monitoring). Level 2: Function monitoring level (detects defective processes of functions in level 1). Level 3: Controller monitoring level (check corrects processing of program commands). The engine control unit (ECU) has determined that the difference between level 2 speed and level 1 speed is greater than 400 RPM. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3283-Sensor supply voltage 2 - 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: 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 725 (R/B) and ground X-937 pin 3, wire 744 (R/Y) and ground X-937 pin 5, wire 4 (R/Y) and ground X-937 pin 28, wire 743 (B/W) 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 17 (55.100.DP-C.20.E.17)

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3285-Sensor supply voltage 3 - 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: 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 725 (R/B) and ground X-937 pin 3, wire 744 (R/Y) and ground X-937 pin 5, wire 4 (R/Y) and ground X-937 pin 28, wire 743 (B/W) 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 17 (55.100.DP-C.20.E.17)

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3301-Fuel metering unit: Maximum negative rail pressure deviation with metering unit on lower limit is 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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Electrical systems - FAULT CODES

3305-Fuel metering unit: Minimum rail pressure exceeded Control Module : ECU Context: The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too low. 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 fallen below a minimum 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 is below the engine speed dependent limit from a curve, established by the ECU, over 2.0 seconds this error will occur. This error is the result of a leak in the high or low pressure side of the fuel rail system. On the high pressure side check for worn or stuck open injector, worn high pressure pump or leaking pressure relief valve. On the low pressure side check for low fuel pressure before or after the gear pump, clogged fuel filter or leakage.

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Electrical systems - FAULT CODES

3309-Fuel metering unit: 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-Timeout of CAN message TSC1-PE torque (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 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

13 14 16 17

(55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

3335-Timeout of CAN message TSC1-PE torque (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 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

13 14 16 17

(55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.17)

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3338-Timeout of CAN message TSC1-VE speed (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 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

13 14 16 17

(55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.17)

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3339-Timeout of CAN message TSC1-VE speed (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 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

13 14 16 17

(55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.17)

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3358-CAN transmit timeout 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

13 14 16 17

(55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

3361-ECM EEPROM - general error Control Module : ECU Context: A functionality for reading, writing and erasing values to a memory media (Flash or EEPROM) is available. These operations are monitored and if problems arise a failure is reported. The sector erase (flash memory) cannot be performed or successfully completed within the engine control unit (ECU). Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3362-Torque to quantity map - not plausible Control Module : ECU Context: The engine control unit (ECU) has detected an error. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3368-Info: Torque limitation due to OBD performance limiter by legislation Control Module : ECU Context: The Engine Control Unit (ECU) has detected an active power reduction due to the OBD performance limiter. This error is for informational purposes and is initiated by a power reduction due to the OBD performance limiter which was caused by too high NOx emissions. Though no action is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation should also be in fault memory. Follow the troubleshooting procedure for that error.

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Electrical systems - FAULT CODES

3374-Injection quantity adjustment failure - invalid EEPROM adjustment value checksum Control Module : ECU Context: The engine control unit (ECU) has determined that the EEPROM Adjustment Value Checksum is invalid. For every individual unit injector an injection quantity adjustment (IMA) can be programmed in the EEPROM for the entire operating range. The monitoring function at hand checks if the EEPROM block holding these quantity adjustment codes can be read successfully and if the cylinder individual checksums of the codes are correct. This monitoring function is carried out at every ECU initialization (reset). Healing can, therefore, only occur by resetting the ECU. This error will occur if the injector quantity adjustment code in the EEPROM of at least one cylinder contains an invalid checksum and the injection quantities will not be corrected with the adjustment values. This error is cleared by resetting (re-initializing) the ECU with a successful read of the injector quantity adjustment values form the EEPROM. This error may be the result of an invalid IMA code being programmed. Try to flash the ECU correctly with correct IMA codes and a proper dataset, if defect persists, replace the ECU.

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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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Electrical systems - FAULT CODES

3405-ECU Power stages: Open load temperature error on the turbocharger PWM output power stage 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-053. 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. 84568014 22/03/2013

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(2) Disconnect the electric valve (WG) connector X-960. (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 (B). 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 18 (55.100.DP-C.20.E.18)

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3408-Lambda sensor: Oxygen concentration implausibly 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 (G/W) and X-943 pin 2, wire 317 (S). 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-053. 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 (G) and X-943 pin 3, wire 314 (G). 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 (O) and X-943 pin 1, wire 316 (O). 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 (Y) and X-943 pin 5, wire 318 (Y). 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 (S) and X-943 pin 2, wire 317 (S). 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 (N) and X-943 pin 6, wire 315 (N). 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 (G) 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 (O) 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 (Y) 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 (S) 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 (N) 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 17 (55.100.DP-C.20.E.17)

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3409-Oil pressure switch: Oil pressure too low (at engine running) 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 (B/W) 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. 84568014 22/03/2013

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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 18 (55.100.DP-C.20.E.18)

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3410-Permanent governor deviation for valve 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 18 (55.100.DP-C.20.E.18)

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3411-Permanent governor deviation for valve 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 18 (55.100.DP-C.20.E.18)

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3414-Short circuit in glow plug 1 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 (R) 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 18 (55.100.DP-C.20.E.18)

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3415-Short circuit in glow plug 3 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 (R/G) 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 18 (55.100.DP-C.20.E.18)

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3416-Short circuit in glow plug 4 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 (R/W) 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 18 (55.100.DP-C.20.E.18)

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3417-Short circuit in glow plug 2 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 (R/B) 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 18 (55.100.DP-C.20.E.18)

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3418-ECU power stages: short circuit to battery error on the turbocharger PWM output power stage 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 (B) 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. 84568014 22/03/2013

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(2) Disconnect the electric valve (WG) connector X-960. (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 18 (55.100.DP-C.20.E.18)

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3419-ECU power stages: Short circuit to ground error on the turbocharger PWM output power stage 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 (B) 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. 84568014 22/03/2013

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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 18 (55.100.DP-C.20.E.18)

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3420-CAN Bus received frames: DFC of auxiliary engine shutdown switch message Control Module : ECU Context: The ECU received a shutdown message via the CAN Bus. This fault code does not indicate a failure but an external shut down request.

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3425-Turbocharger: Over boost deviation at P2 too high in pressure charger regulator Control Module : ECU Context: The boost pressure exceeds the maximum limit for a period greater than 10 s. Cause: The Engine Control Unit (ECU) is detecting inaccurate boost pressure. Possible failure modes: 1. Faulty wiring 2. Faulty boost pressure sensor 3. Faulty variable geometry turbocharger (VGT) 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 VGT 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.

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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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3427-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter low Control Module : ECU Context: The engine control unit (ECU) has detected the DPF filter flow resistance is low. Check that the DPF filter is installed properly. If the DPF filter is not installed properly, refit the DPF filter correctly. If damaged is determined, replace the DPF filter. This fault will clear at the end of the next regeneration cycle. If the error still persists, check for other DPF related error codes and continue to those tests.

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3428-Diesel particulate filter pressure sensor: Not plausibility error 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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3429-Diesel particulate filter pressure sensor: Hoseline plausibility error Control Module : ECU Context: If the hose connection upstream from the diesel particulate filter becomes detached or is completely blocked atmospheric pressure is constantly present at the pressure connection upstream from the diesel particulate filter. Since the pressure downstream from the diesel particulate filter is above the atmospheric pressure during operation, the differential pressure signal will continuously show negative values. The engine control unit (ECU) has detected the differential pressure signal is less than 1.0 kPa (0.1 psi) during the cold condition. This fault is a cause of a hose connection upstream from the diesel particulate filter not being attached, or is blocked. Check mounting of the hose lines, and check the hose line is not blocked.

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3430-EGR inducement less severe derating level Control Module : ECU Context: Legislations require special measures to induce proper functionality of the EGR system. EGR system related faults are monitored and trigger different warnings and reactions. The inducements starts with a driver warning, then a torque reduction follows and if the fault is not fixed, a creep mode with a strongly reduced maximum vehicle speed is activated. A failure which will trigger an inducement is ‘EGR valve blocked’. If at least one error belonging to 'EGR valve blocked’ group is set, the timer for inducement level 1 (torque reduction) is increased. When timer exceeds 0 s and at least one error belonging to the triggered group is active, level 1 for "EGR valve blocked" group is set. The engine control unit (ECU) has detected a fault with the EGR valve and inducement level 1 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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3431-EGR Inducement most severe derating level Control Module : ECU Context: Legislations require special measures to induce proper functionality of the EGR system. EGR system related faults are monitored and trigger different warnings and reactions. The inducements starts with a driver warning, then a torque reduction follows and if the fault is not fixed, a creep mode with a strongly reduced maximum vehicle speed is activated. A failure which will trigger an inducement is ‘EGR valve blocked’. If at least one error belonging to 'EGR valve blocked’ group is set, the timer for inducement level 3 (creep mode) is increased. When timer exceeds 4 h and at least one error belonging to the triggered group is active, level 3 for "EGR valve blocked" group is set. The engine control unit (ECU) has detected a fault with the EGR valve and inducement level 3 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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3433-Diesel particulate filter (DPF) inducement less severe derating level Control Module : ECU Context: Legislations require special measures to induce proper functionality of the EGR system. EGR system related faults are monitored and trigger different warnings and reactions. The inducements starts with a driver warning, then a torque reduction follows and if the fault is not fixed, a creep mode with a strongly reduced maximum vehicle speed is activated. A failure which will trigger an inducement is ‘DPF inducement’. If at least one error belonging to 'DPF inducement ’ group is set and the engine is running, the timer for inducement level 1 (less severe torque reduction) is increased. When timer exceeds 0 s and at least one error belonging to the triggered group is active, level 1 for "DPF inducement’ group is set. The engine control unit (ECU) has detected a fault with the diesel particulate filter (DPF) and inducement level 1 due to ‘DPF inducement’ has been activated. Check for other error codes relating the to the DPF and continue to these tests.

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3434-Diesel particulate filter (DPF) inducement most severe derating level Control Module : ECU Context: Legislations require special measures to induce proper functionality of the EGR system. EGR system related faults are monitored and trigger different warnings and reactions. The inducements starts with a driver warning, then a torque reduction follows and if the fault is not fixed, a creep mode with a strongly reduced maximum vehicle speed is activated. A failure which will trigger an inducement is ‘DPF inducement’. If at least one error belonging to 'DPF inducement ’ group is set and the engine is running, the timer for inducement level 3 (more severe torque reduction) is increased. When timer exceeds 4 h and at least one error belonging to the triggered group is active, level 3 for "DPF inducement’ group is set. The engine control unit (ECU) has detected a fault with the diesel particulate filter (DPF) and inducement level 3 due to ‘DPF inducement’ has been activated. Check for other error codes relating the to the DPF and continue to these tests.

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3517-Ambient 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 (O) 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 (O) and ground. X-942 pin 2, wire 328 (O/B) 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 17 (55.100.DP-C.20.E.17)

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3518-Ambient 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 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 (O) 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 (O) 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 (O). 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 (O/B) 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 (O/B) 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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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3616-Torque limitation due to turbo charger protection Control Module : ECU Context: The Engine Control Unit (ECU) has detected an active power reduction due to turbo charger protection mainly in high altitude, which was not caused by a failure but an extreme working condition which duration is longer than 120 s. This error is for informational purposes and is initiated by a power reduction due to turbo charger protection being active causing a torque limitation greater than 25 % of the desired torque for longer than 120 s and is reset once the torque limitation due to turbo charger protection is no longer active. Though no action is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation should also be in fault memory. Follow the troubleshooting procedure for that error.

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3648-Turbocharger: P2 pressure errors in PCR - pressure deviation too high Control Module : ECU Context: If fault code is present refer to 3425-Turbocharger: Over boost deviation at P2 too high in pressure charger regulator (10.501) for troubleshooting.

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3650-Battery voltage: Source high for battery voltage sensor 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 725 (R/B) and ground X-937 pin 3, wire 744 (R/Y) and ground X-937 pin 5, wire 4 (R/Y) and ground X-937 pin 28, wire 743 (B/W) 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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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3651-Battery voltage: Source low for battery voltage sensor 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 725 (R/B) and ground X-937 pin 3, wire 744 (R/Y) and ground X-937 pin 5, wire 4 (R/Y) and ground X-937 pin 28, wire 743 (B/W) 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 17 (55.100.DP-C.20.E.17)

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3652-CAN Bus: Bus off of CAN 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 (Y) and X-450 ( CAN_H) pin 3, wire 0.75 (Y) X-937 ( CAN_H) pin 46, wire 0.75 (Y) and X-450 ( CAN_H) pin 3, wire 0.75 (Y) X-937 ( CAN_L) pin 25, wire 0.75 (G) and X-450 ( CAN_L) pin 4, wire 0.75 (G) X-937 ( CAN_L) pin 47, wire 0.75 (G) and X-450 ( CAN_L) pin 4, wire 0.75 (G) 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 harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical Electrical

schematic schematic schematic schematic schematic

frame frame frame frame frame

01 (55.100.DP-C.20.E.01) 11 (55.100.DP-C.20.E.11) 16 (55.100.DP-C.20.E.16) 16 (55.100.DP-C.20.E.16) 17 (55.100.DP-C.20.E.17)

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3655-Torque limitation, engine protection: General report of the event of torque limitations Control Module : ECU Context: This is an information fault code only. The fault code is logged and indicates that engine torque has been limited. Troubleshoot the fault codes that cause the reduction in power.

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3656-Torque limitation, engine protection: Torque limitation caused by particulate filter Control Module : ECU Context: This is an information fault code only. The fault code is logged and indicates that engine torque has been limited due to a restriction in the particulate filter. Troubleshoot the fault codes that cause the reduction in power.

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3657-CAN Bus Received frames: Timeout error of CAN receive-frame CM1BC 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 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

13 14 16 17

(55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.17)

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3663-EGR command saturation over higher threshold 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3664-EGR command saturation over lower threshold 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3665-Permanent governor deviation for valve 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3666-Permanent governor deviation for valve 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3667-Open load error for 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 (S) 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 (G) 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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(6) Measure the resistance between ECU connector X-939 pin 39, wire 411 (R) 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 (N/Y) 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3668-Over temperature error for H-bridge 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 (S) 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.

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(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 (S) 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3669-Short circuit to battery on Out1 error for H-bridge 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 (S) 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.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3670-Short circuit to battery on Out2 error for H-bridge 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 (S) 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.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3671-Short circuit to ground on Out1 error for H-Bridge 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 (S) 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. (1) Turn the key switch OFF.

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(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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3672-Short circuit to ground on Out2 error for H-Bridge 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 (S) 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. (1) Turn the key switch OFF.

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(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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3673-Short circuit over load error for H-bridge 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 (S) 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. (2) Disconnect the EGR valve connector X-964.

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(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 ÎŠ. A. The resistance is greater than 20,000 ÎŠ. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. B. The resistance is less than 20,000 ÎŠ. 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3674-Under voltage error for H-bridge 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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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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3676-EGR valve position sensor voltage source 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 (G) to X-939 pin 39, wire 411 (R). (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 (N/Y) to X-939 pin 39, wire 411 (R).

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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 (G) 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 (R) 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 (N/Y) 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3677-EGR valve position sensor voltage source 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 (G) to chassis ground. The resistance should be greater than 20,000 立. Wiggle the harness during measurement to reveal an intermittent condition. (3) Measure the resistance from ECU connector X-939 pin 39, wire 411 (R) to chassis ground. The resistance should be greater than 20,000 立 . Wiggle the harness during measurement to reveal an intermittent condition. (3) Measure the resistance from ECU connector X-939 pin 24, wire 402 (N//Y) 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.

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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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3680-Injection cut off: Injection cut off demand for shut off coordinator Control Module : ECU Context: This fault is triggered when the Engine Control Unit (ECU) has an internal failure that concerns the reliability of the accelerator pedal signal, fuel injection parameters or engine speed failures are detected. Another fault will be active when this fault occurs. Refer to other fault present. Correct that fault, and erase fault codes.

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3688-Water sensor in the fuel filter: WIF sensor check is failed 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 (O) 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 (B) 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 (Y) and X-937 pin 30, wire 347 (Y). 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 (Y) 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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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3689-DFC for faulty diagnostic data transmission or protocol error 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 (O/W) 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. 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. 84568014 22/03/2013

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(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 (B) and ECU connector X-937 pin 41, wire 333 (U/R). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Pay particular attention to the splice area, SP-138 . (4) Measure the resistance between connector X-938 pin 8, wire 678 (S) and ECU connector X-937 pin 52, wire 332 (S). 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 and ECU connector X-937 pin 22, wire 334 (N/Y). 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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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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3691-No load error for low voltage system 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3692-Over temperature error on ECU power stage for glow plug low voltage system 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 (O/W) 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. 84568014 22/03/2013

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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 (B) and ECU connector X-937 pin 41, wire 333 (U/R). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Pay particular attention to the splice area, SP-138 . (4) Measure the resistance between connector X-938 pin 8, wire 678 (S) and ECU connector X-937 pin 52, wire 332 (S). 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 and ECU connector X-937 pin 22, wire 334 (N/Y). 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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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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3693-Short circuit to battery error for low voltage system 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 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.

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(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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3694-Short circuit to ground error for low voltage system 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 (O/W) 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. 84568014 22/03/2013

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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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3702-Injection control: Detection of failed engine start Control Module : ECU Context: The engine did not start due a problem with engine speed or rail pressure. Troubleshoot the reasons why the engine could not maintain a stating speed or insufficient fuel rail pressure.

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3703-Injection control: Check of minimum rail pressure Control Module : ECU Context: This fault has been generated due to the injector control pressure is too low. Check for more specific failures related to the rail pressure system. If no other faults are active, check the rail injectors are not damaged. Also, check for any rail or injector leakages and check the main fuel filter is not blocked. If any damage, leakages or blockages are found, repair or replace necessary components.

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3704-Injector adjustment programming: Check of missing injector adjustment value programming Control Module : ECU Context: This fault has been generated due to the injector 2 programming being incorrect. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Using the Electronic Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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3705-Injector adjustment programming: Check of missing injector adjustment value programming Control Module : ECU Context: This fault has been generated due to the injector 3 programming being incorrect. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Using the Electronic Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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3706-Injector adjustment programming: Check of missing injector adjustment value programming Control Module : ECU Context: This fault has been generated due to the injector 4 programming being incorrect. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Using the Electronic Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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3707-Lambda sensor: Open circuit at the lambda sensor 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 (G) 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 (N) 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 (N). 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 (N). There should be continuity. 84568014 22/03/2013

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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 (N) 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.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3708-Lambda sensor: Open circuit at the lambda sensor pump current pin - IP (lambda = 1 detection) 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 (G) 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 (O) 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 (O). 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 (O). There should be continuity. 84568014 22/03/2013

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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 (O). 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.

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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

3709-Lambda sensor: Open circuit at the lambda sensor 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 (G) 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 (S) 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 (S). 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 (S). There should be continuity. 84568014 22/03/2013

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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 (S). 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.

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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

3712-Lambda sensor: SCG 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 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 (G) 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 (G) 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 (G). 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 (G). The resistance should be less than 10.0 立.

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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 (G). 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.

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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

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 (G) 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 (G). 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 (G). 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.

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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

3714-Lambda sensor: Fault code to indicate source high error for O2 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 (G) 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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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

3715-Lambda sensor: Fault code to indicate source low error for O2 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 (G) 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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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

3716-Lambda sensor: O2 value above the max threshold 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 (G) 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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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

3720-Lambda sensor: Low battery voltage at the SPI chip 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 (O) X-937 pin 85, wire 317 (S) X-937 pin 7, wire 314 (G) X-937 pin 86, wire 318 (Y) X-937 pin 63, wire 315 (N)

To X-943 pin 1, wire 316 (O) X-943 pin 2, wire 317 (S) X-943 pin 3, wire 314 (G) X-943 pin 5, wire 318 (Y) X-943 pin 6, wire 315 (N)

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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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

3722-Lambda sensor temperature Ri exceeds the maximum limit 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 (O) X-937 pin 85, wire 317 (S) X-937 pin 7, wire 314 (G) X-937 pin 86, wire 318 (Y) X-937 pin 63, wire 315 (N)

To X-943 pin 1, wire 316 (O) X-943 pin 2, wire 317 (S) X-943 pin 3, wire 314 (G) X-943 pin 5, wire 318 (Y) X-943 pin 6, wire 315 (N)

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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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

3723-Lambda sensor temperature Ri is below the minimum limit 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 (O) X-937 pin 85, wire 317 (S) X-937 pin 7, wire 314 (G) X-937 pin 86, wire 318 (Y) X-937 pin 63, wire 315 (N)

To X-943 pin 1, wire 316 (O) X-943 pin 2, wire 317 (S) X-943 pin 3, wire 314 (G) X-943 pin 5, wire 318 (Y) X-943 pin 6, wire 315 (N)

Result Continuity Continuity Continuity Continuity Continuity

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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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55.11 [55.DTC] / 421

Electrical systems - FAULT CODES

3724-Lambda sensor: Short to battery at IA, IP, UN, VG 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 (O) X-943 pin 2, wire 317 (S) X-943 pin 5, wire 318 (Y) X-943 pin 6, wire 315 (N)

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 (S) to connector X-943 pin 2, wire 317 (S). 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 (S). 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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55.11 [55.DTC] / 422

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

3725-Lambda sensor: Short to ground at IA, IP, UN, VG 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 (O) X-943 pin 2, wire 317 (S) X-943 pin 5, wire 318 (Y) X-943 pin 6, wire 315 (N)

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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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

3727-Info: Low oil viscosity Control Module : ECU Context: This fault is the result of the oil viscosity breaking down below a first threshold. Once this fault is present, it remains active until the oil is changed. Change the engine oil, and clear any fault codes present.

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Electrical systems - FAULT CODES

3728-Info: Too low oil viscosity Control Module : ECU Context: This fault is the result of the oil viscosity breaking down below a first threshold. Once this fault is present, it remains active until the oil is changed. Change the engine oil, and clear any fault codes present.

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Electrical systems - FAULT CODES

3735-Fuel metering unit: Over temperature of device driver of metering unit 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 (S/W) to pin 15, wire 400 (N/G). 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 (N/G). 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 (S/W). 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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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

3736-Lambda sensor: O2 concentration is outside the predefined window during heater coupling detection 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.

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Electrical systems - FAULT CODES

3737-Lambda sensor: Over temperature 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: 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 (G) 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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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

3738-Analog digital convertor (ADC): Diagnostic fault check to report multiple errors while checking the complete ROM-memory Control Module : ECU Context: This failure can be the result of corrupted data or internal failure of the engine control unit (ECU). Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3739-Power stages, injector: Loss of synchronization Control Module : ECU Context: The engine control unit (ECU) has detected a processing error during ECU start up. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3740-Power stages, injector: DFC to set a torque limitation once an error is detected before MoCSOP's error reaction is set Control Module : ECU Context: If this fault is occurs, check for any other faults associated with the injectors. If other faults are present, correct those faults first. Clear any faults codes that exist and recheck this fault has cleared. If no other codes are present, try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3741-Power stages, injector: Wrong set response time Control Module : ECU Context: If the engine control unit (ECU) times out during start up, this fault will occur. Try to flash the ECU correctly with the proper data set. If the fault persists, replace the ECU.

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Electrical systems - FAULT CODES

3742-Power stages, injector: Too many SPI errors during MoCSOP execution Control Module : ECU Context: If the during start up the engine control unit (ECU) detects a faulty communication over SPI during the shut off path test, this fault will occur. Try to flash the ECU correctly with the proper data set. If the fault persists, replace the ECU.

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Electrical systems - FAULT CODES

3743-Power stages, injector: Diagnostic fault check to report the error in under voltage monitoring Control Module : ECU Context: If the engine control unit (ECU) detects under voltage in the ECU during start up, this fault will occur. Try to flash the ECU correctly with the proper data set. If the fault persists, replace the ECU.

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Electrical systems - FAULT CODES

3744-Power stages, injector: Diagnostic fault check to report the error in over voltage monitoring Control Module : ECU Context: If the engine control unit (ECU) detects over voltage in the ECU during start up, this fault will occur. Try to flash the ECU correctly with the proper data set. If the fault persists, replace the ECU.

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Electrical systems - FAULT CODES

3745-Power stages, injector: Diagnostic fault check to report that WDA is not working correctly Control Module : ECU Context: If during start up the engine control unit (ECU) detects an implausible response in the power stage feedback during the shut off path test in the ECU, this fault will occur. Try to flash the ECU correctly with the proper data set. If the fault persists, replace the ECU.

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Electrical systems - FAULT CODES

3746-Power stages, injector: OS timeout in the shut off path test. Failure setting the alarm task period Control Module : ECU Context: If during start up the engine control unit (ECU) detects an alarm task cannot be set or reset after having detected a timeout problem during the shut off test path in the ECU, this fault will occur. Try to flash the ECU correctly with the proper data set. If the fault persists, replace the ECU.

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Electrical systems - FAULT CODES

3747-Power stages, injector: Diagnostic fault check to report that the positive test failed Control Module : ECU Context: If during start up the engine control unit (ECU) detects an irreversible error bit set in the ECU, this fault will occur. Try to flash the ECU correctly with the proper data set. If the fault persists, replace the ECU.

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Electrical systems - FAULT CODES

3748-Power stages, injector: Diagnostic fault check to report the timeout in the shut off path test Control Module : ECU Context: If during start up the engine control unit (ECU) detects a timeout in the power stage feedback during the shut off path test in the ECU, this fault will occur. Try to flash the ECU correctly with the proper data set. If the fault persists, replace the ECU.

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Electrical systems - FAULT CODES

3750-Injection control: Error in the plausibility of the injection energizing time Control Module : ECU Context: The engine control unit (ECU) has detected an implausible injection energizing time for either pilot main or postinjection, if the difference between measured and programmed injection duration is greater than 50 ms. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3751-Injection control: Error in the plausibility of the start of energizing angles Control Module : ECU Context: The engine control unit (ECU) has detected an implausible start of energizing of either main or a pilot or a postinjection. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3752-Zero Fuel Calibration (ZFC): Error in the plausibility of the energizing times of the zero fuel quantity calibration Control Module : ECU Context: The engine control unit (ECU) has detected the energizing times of the zero fuel quantity or zero fuel low idle calibrations are outside of the tolerance range. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3753-Level 2 monitoring: Diagnostic fault check to report the error due to injection quantity correction Control Module : ECU Context: An incorrect data set calibration or fatal error within the engine control unit (ECU) has occurred. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3754-Level 2 monitoring: Diagnostic fault check to report the plausibility error in rail pressure monitoring Control Module : ECU Context: An incorrect data set calibration or fatal error within the engine control unit (ECU) has occurred. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3755-Level 2 monitoring: Diagnostic fault check to report the error due to torque comparison Control Module : ECU Context: An incorrect data set calibration or fatal error within the engine control unit (ECU) has occurred. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3756-Level 2 monitoring: Diagnosis fault check to report the demand for normal mode due to an error in the post injection 2 quantity Control Module : ECU Context: The total fuel quantity contributing to torque generation is determined from the addition of pilot injections, main injection plus the product of post injection 2 and 3 and their efficiency. The engine control unit (ECU) has detected either the efficiency of post injection 2 is out of its plausible value range, the starting angle of post Injection 2 is out of range, an implausibility is detected during monitoring of the operation mode or the transition between two modes is taking too long. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3757-Level 2 monitoring: Diagnosis fault check to report the error to demand for an ICO due to an error in the post injection 2 shut off Control Module : ECU Context: The total fuel quantity contributing to torque generation is determined from the addition of pilot injections, main injection plus the product of post injection 2 and 3 and their efficiency. The engine control unit (ECU) has detected the post injection 2 quantity exceeds a limit of 5.0 mg in normal mode. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3758-Level 2 monitoring: Diagnosis fault check to report the error to demand for an ICO due to an error in the post injection 3 efficiency factor Control Module : ECU Context: The total fuel quantity contributing to torque generation is determined from the addition of pilot injections, main injection plus the product of post injection 2 and 3 and their efficiency. The engine control unit (ECU) has detected implausible post injection 3 efficiencies. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3759-Level 2 monitoring: Diagnosis of curr path limitation forced by ECU monitoring level 2 Control Module : ECU Context: The torque request can be influenced from many vehicle functions (accelerator pedal, transmission etc) which are in some cases additive, in some cases as maximum and in some case as limitation. The finally requested torque on the engine must not be similar to the engine torque output, as the request takes into consideration system tolerances (e.g. due to learning factors, but also due to temperatures and pressures), i.e. the final torque request is "virtual" in the way, that the real torque would be correct. As fuel pressure control is dependant on the torque input, the "virtual" torque request would lead to a wrong set point and therefore to wrong emissions. Therefore the input torque for the fuel pressure control is calculated separately called "Lead torque". This complex structure can lead to a "lead" torque request, which is higher than accepted by engine. Therefore the total requested "lead" torque is compared to a maximal allowed (inner) torque. If the requested torque is higher, the system layout is not correct (calibration error in one of the electronic vehicle controllers) and a failure is stored. If this fault occurs a fatal error within the engine control unit (ECU) or an incorrect data set calibration of the electronic vehicle controller or ECU has occurred. Check for other error codes in the vehicle controllers and continue to fix these errors. If no other vehicle controller errors are present, try to flash the vehicle controller with the proper data set and perform the calibration procedures. If the error persists, try to flash the ECU correctly with the proper data set. If the error still persists, replace the ECU.

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Electrical systems - FAULT CODES

3760-Level 2 monitoring: Diagnosis air path limitation due to a functional control unit monitoring forced by ECU monitoring level 2 Control Module : ECU Context: The torque request can be influenced from many vehicle functions (accelerator pedal, transmission etc) which are in some cases additive, in some cases as maximum and in some case as limitation. The finally requested torque on the engine must not be similar to the engine torque output, as the request takes into consideration system tolerances (e.g. due to learning factors, but also due to temperatures and pressures), i.e. the final torque request is "virtual" in the way, that the real torque would be correct. As the air control (Boost pressure, EGR rate etc) is dependant on the torque input, the "virtual" torque request would lead to a wrong set point and therefore to wrong emissions. Therefore the input torque for the Air control is calculated separately - called "Lead torque". This complex structure can lead to a "lead" torque request, which is higher than accepted by engine. Therefore the total requested "lead" torque is compared to a maximal allowed (inner) torque. If the requested torque is higher, the system layout is not correct (calibration error in one of the electronic vehicle controllers) and a failure is stored. If this fault occurs a fatal error within the engine control unit (ECU) or an incorrect data set calibration of the electronic vehicle controller or ECU has occurred. Check for other error codes in the vehicle controllers and continue to fix these errors. If no other vehicle controller errors are present, try to flash the vehicle controller with the proper data set and perform the calibration procedures. If the error persists, try to flash the ECU correctly with the proper data set. If the error still persists, replace the ECU.

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Electrical systems - FAULT CODES

3761-Level 2 monitoring: Diagnosis quantity path limitation due to a functional control unit monitoring (level 2) Control Module : ECU Context: The torque request can be influenced from many vehicle functions (accelerator pedal, transmission etc) which are in some cases additive, in some cases as maximum and in some case as limitation. This complex structure can lead to a "lead" torque request, which is higher than accepted by engine. Therefore the total requested "lead" torque is compared to a maximal allowed (inner) torque. If the requested torque is higher, the system layout is not correct (calibration error in one of the electronic vehicle controllers) and a failure is stored. If this fault occurs a fatal error within the engine control unit (ECU) or an incorrect data set calibration of the electronic vehicle controller or ECU has occurred. Check for other error codes in the vehicle controllers and continue to fix these errors. If no other vehicle controller errors are present, try to flash the vehicle controller with the proper data set and perform the calibration procedures. If the error persists, try to flash the ECU correctly with the proper data set. If the error still persists, replace the ECU.

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Electrical systems - FAULT CODES

3762-Level 2 monitoring: Reported overvoltage of supply 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, wire 725 (R/B) and ground X-937 pin 3, wire 744 (R/Y) and ground X-937 pin 5, wire 4 (R/Y) and ground X-937 pin 28, wire 743 (B/W) 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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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

3763-Level 2 monitoring: Reported under voltage of supply 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, wire 725 (R/B) and ground X-937 pin 3, wire 744 (R/Y) and ground X-937 pin 5, wire 4 (R/Y) and ground X-937 pin 28, wire 743 (B/W) 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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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

3764-Main relay: Early opening defect of main relay 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 â&#x20AC;&#x2DC;After-runâ&#x20AC;&#x2122; 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 K200 . 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 K200. A. Remove the ECU main relay K200 and check the operation of the relay. If the relay does not operate correctly, replace the ECU main relay K200. 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 K200. Turn the ignition key switch ON. Measure the voltage between connector X-937 pin 54, wire 341 (O). 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: K200 terminal 30 to ground K200 terminal 86 to ground If approximately 12 V is not indicated, repair or replace the harness as required. 84568014 22/03/2013

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B. If approximately 12 V is indicated , continue to step 6 6. Check the ECU main relay fuses F-051 and F-052. 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: K200 terminal 87 to connector X-937 pin 1, wire 745 (R/B) K200 terminal 87 to connector X-937 pin 3, wire 744 (R/Y) K200 terminal 87 to connector X-937 pin 5, wire 4 (R/Y) K200 terminal 85 to connector X-937 pin 28, wire 743 (B/W) 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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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 01 (55.100.DP-C.20.E.01) Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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Electrical systems - FAULT CODES

3767-ECU internal: Diagnostic fault check to report 'WDA active' due to errors in query/response communication Control Module : ECU Context: Communication between CJ945 (power stage chips) and CY320 (power stage voltage supplier) is monitored. The engine control unit (ECU) has detected an unexpected communication (wire active when it should not be). Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3768-ECU internal: Diagnostic fault check to report 'ABE active' due to under voltage detection Control Module : ECU Context: Communication between CJ945 (power stage chips) and CY320 (power stage voltage supplier) is monitored. The engine control unit (ECU) has detected the ABE wire between CJ945 (power stage chips) and CY320 (power stage voltage supplier) is active due to undervoltage detection. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3769-ECU internal: Diagnostic fault check to report 'ABE active' due to overvoltage detection Control Module : ECU Context: Communication between CJ945 (power stage chips) and CY320 (power stage voltage supplier) is monitored. The engine control unit (ECU) has detected an active ABE wire due to overvoltage. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3770-ECU internal: Diagnostic fault check to report 'WDA/ABE active' due to unknown reason Control Module : ECU Context: Communication between CJ945 (power stage chips) and CY320 (power stage voltage supplier) is monitored. The engine control unit (ECU) has detected an active WDA/ABE communication wire due to an unknown reason. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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Electrical systems - FAULT CODES

3773-Turbocharger: Under boost detected in pressure charger regulator Control Module : ECU Context: The turbocharger regulator is monitored for any deviation of actual boost pressure from target pressure . Cause: Under boost is detected if the engine is running within the specified working area and a positive boost pressure deviation is detected for at least 10 s while the following conditions are met: • Engine speed between 1000 - 4000 RPM • Fuel quantity is greater than 10 mg/hub • Engine coolant temperature is greater than 44.96 °C (112.9 °F) • Boost pressure sensor signal must be recognized as intact • No regeneration requests from the diesel particulate filter (DPF) management • Boost pressure governing is active • No engine torque limitation, except smoke limitation is active Possible failure modes: 1. Clogged air filter/intake system 2. Faulty turbocharger hoses 3. Faulty turbocharger actuator 4. Faulty turbocharger 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 the air filter. Remove and inspect the air filter. A. If the air filter is restricted, clean or replace the air filter. B. If the air filter is free of restrictions, continue to step 3. 3. Check the intake system. Check for signs of restriction in the intake system. A. If the intake is clogged, clean out intake system. If intake is damaged, replace the intake system. B. If intake is free of restrictions, continue to step 4. 4. Check the turbocharger system hoses. Check the turbocharger system hoses are connected and free from of air leaks and restrictions. A. If a problem is found with the turbocharger hoses, repair or replace as required. B. If the turbocharger hoses are okay, continue to step 5. 5. Check condition of turbocharger. Remove connectors from the turbocharger. Visually inspect the blades, actuator and turbocharger housing for any damage. A. If any damage is found, replace the turbocharger.

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Electrical systems - FAULT CODES

B. If the turbocharger is visually in good condition, check the operation of the turbocharger actuator.

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3786-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter - high Control Module : ECU Context: The engine control unit (ECU) has detected the soot level in the DPF filter is exceeding the threshold limit, or the flow resistance is high. If this fault occurs, black smoke should be visible at the exhaust pipe. Check that the DPF filter is mounted properly and is not cracked. If the DPF filter is not mounted properly, refit the DPF filter correctly. If damaged is determined, replace the DPF filter. This fault will clear at the end of the next regeneration cycle.

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3787-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter - very high Control Module : ECU Context: The engine control unit (ECU) has detected the soot level in the DPF filter is exceeding the threshold limit, or the flow resistance is high. Check that the DPF filter is mounted properly and is not cracked. If the DPF filter is not mounted properly, refit the DPF filter correctly. If damaged is determined, replace the DPF filter. This fault will clear at the end of the next regeneration cycle.

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3789-Regeneration duration exceeds maximum allowed duration Control Module : ECU Context: The engine control unit (ECU) has detected the regeneration cycle did not complete in time. This could be a cause of exhaust restrictions, differential pressure sensor measuring wrong. Check the exhaust for any kind of restrictions. Check rear differential pressure sensor hose is not clogged. Perform the manual regeneration procedure.

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3790-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter - maximum 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 (Y/B) and X-947 pin 2, wire 330 (Y/N). 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 (Y) to X-947 pin 3, wire 331 (Y). 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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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3794-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor 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 (R/B) 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 84568014 22/03/2013

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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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3795-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor 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 (R/B) 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 84568014 22/03/2013

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3797-Diesel particulate filter pressure sensor: SRC high for PFlt differential pressure sensor 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 Approx. 0 - 0.10 ohms (Y/B) X-937 pin 36, wire 330 Approx. 0 - 0.10 ohms (Y/N)

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3. Continuity 5. Shorts

6. Shorts

X-947 pin 3 X-937 pin 58, wire 331 (Y) Approx. 0 - 0.10 ohms X-937 pin 58, wire 331 (Y) X-937 pin 14, wire 329 Open Circuit (Y/B), pin 36, wire 330 (Y/N) X-937 pin 36, wire 330 X-937 pin 14, wire 329 Open Circuit (Y/N) (Y/B)

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

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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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3798-Diesel particulate filter pressure sensor: SRC low for PFlt differential pressure sensor 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 (Y/B) 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 (Y/B). 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 (Y/B) to pin 2, wire 330 (Y/N). 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 (Y/B) to connector X-937 pin 14, wire 329 (Y/B). 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 (Y/B) and connector X-937 pin 14, wire 329 (Y/B).. Locate and repair damaged wiring.

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B. If there is continuity, leave connector X-937 disconnected. Continue with step 10. 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-939. Use a multi-meter to check for continuity from the engine harness side of connector X-947 pin 2, wire 330 (Y/N) 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 (Y/N). 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 (Y/N) to pin 3, wire 331 (Y). 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 (Y) to connector X-937 pin 58, wire 331 (Y). 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 (Y) and connector X-937 pin 58, wire 331 (Y). 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-939 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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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3799-Pressure relief valve: Pressure relief valve is forced to open, perform pressure shock Control Module : ECU Context: This code is not an actual failure. A rail pressure shock test was detected. Clear code and return machine to proper use.

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3800-Pressure relief valve: Quantity balance check if a successful PRV opening is ensured Control Module : ECU Context: This code is not a failure fault, the engine control unit (ECU) has detected the pressure shock was rejected because fuel quantity is not in range. To determine mechanical wear out, the pressure relief valve can be forced open by a pressure shock, when the metering valve of the high pressure fuel pump is set to maximum possible quantity. Pressure shock is only possible in a defined engine speed range depending on rail pressure.

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3801-Turbine upstream pressure sensor: Source high for turbine upstream pressure sensor 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.

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A. Check between connector X-939 pin 43, wire 414 (R/U) and X-963 pin 3. If an open circuit is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the turbine upstream pressure sensor.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3802-Turbine upstream pressure sensor: Source low for turbine upstream pressure sensor 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.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3803-ECU internal: Error on R2S2 module (low level chip driver for the power stage chips) Control Module : ECU Context: The engine control unit (ECU) has detected an internal communication failure of several signals in the ECU due, for example, to the supply voltage over the threshold. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the ECU.

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3808-Fuel metering unit: set point of metering unit not plausible Control Module : ECU Context: This fault is a result of a leak on the high or low pressure side of the high side pressure pump. Check for worn or stuck open injector, worn high pressure pump or leaking pressure control valve. Check for low fuel pressure before or after the gear pump, clogged fuel filter or leakage, or faulty fuel pump.

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Electrical systems - FAULT CODES

3810-Fuel pressure sensor: rail pressure raw value is intermittent 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 18 (55.100.DP-C.20.E.18)

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3811-ECU sensor supply monitor: ECU internal: Error sensor supplies 1 Control Module : ECU Context: The ECM provides 3 independent 5V voltage supplies for the sensors. These sensor supply voltages are monitored to ensure they remain within a given range. Cause: The sensor 5 volt supply is out of range. Possible failure modes: 1. High system voltage 2. High engine temperatures 3. Faulty wiring 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 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, download the correct level of software. If the fault is still present, remove and replace the ECU.

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3812-Physical range check high for ECU temperature sensor Control Module : ECU Context: The ECU detected an internal temperature above 130 Â°C (266 Â°F). 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. High system voltages can contribute to this fault. Verify that the system voltage is correct and that there is not a problem with the alternator charging system. Possible failure modes: 1. High engine temperatures 2. High system voltage 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 3812 is active with other fault codes such as FC3051 or FC3518 or FC3007. Troubleshoot these fault codes before troubleshooting FC3812. B. Fault code 3812 is not recorded again. OK to return the machine to service. C. Fault code 3812 is active and recorded again. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault.

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3813-Physical range check low for ECU temperature sensor Control Module : ECU Context: The ECU detected an internal temperature below the -40 Â°C (-40 Â°F). This fault can be caused by low environmental temperatures. If the environmental temperature is not too low and the machine has not been used heavily, let the engine warm up. Low system voltages can contribute to this fault. Verify that the system voltage is correct and that there is not a problem with the alternator charging system. Possible failure modes: 1. Low engine temperatures 2. Low system voltage 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 low battery voltage to the ECU or low fluid temperatures. A. Fault code 3813 is active with other fault codes such as FC3052 or FC3008. Troubleshoot these fault codes before troubleshooting FC3813. B. Fault code 3813 is not recorded again. OK to return the machine to service. C. Fault code 3813 is active and recorded again. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault.

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3814-ECU temperature sensor: SPI Error ECU temperature sensor (LM71) Control Module : ECU Context: The ECU detected an internal temperature above 130 Â°C (266 Â°F). 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. High system voltages can contribute to this fault. Verify that the system voltage is correct and that there is not a problem with the alternator charging system. Possible failure modes: 1. High engine temperatures 2. High system voltage 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 3814 is active with other fault codes such as FC3051 or FC3518 or FC3007. Troubleshoot these fault codes before troubleshooting FC3814. B. Fault code 3814 is not recorded again. OK to return the machine to service. C. Fault code 3814 is active and recorded again. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault. .

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3818-Open load error for power stage 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 (R/Y) 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 (O/W) 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 (B/Y) 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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(6) Measure the resistance between ECU connector X-939 pin 53, wire 419 (S/B) 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/G) 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.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3819-Over current error for H-bridge 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 (R/Y) 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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(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 (R/Y) 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 (O/W) 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.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3820-Over temperature error for H-bridge 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 (R/Y) 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3821-Short circuit to battery on Out1 error for H-bridge 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 (R/Y) 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 (O/W) 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.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3822-Short circuit to battery on Out2 error for H-bridge 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 X-939. (3) Turn the key switch ON. (4) Measure the voltage from ECU connector X-939 pin 49, wire 416 (R/Y) 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 (O/W) 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.

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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3823-Short circuit to ground on Out1 error for H-bridge 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 (R/Y) 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 (O/W) 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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(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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3824-Short circuit to ground on Out2 error for H-Bridge 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 (R/Y) 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 (O/W) 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. (1) Turn the key switch OFF.

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(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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3826-Temperature dependent over current error for H-bridge 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 (R/Y) and ECU connector X-939 pin 34, wire 407 (O/W). 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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(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.

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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

3827-Under voltage error for H-bridge 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.

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3834-ECU Power stages: Throttle valve actuator power stage source 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 (B/Y) and pin 53, wire 419 (S/B). 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 (S/B) and pin 37, wire 409 (TQ/G). 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 (B/Y) to chassis ground X-939 pin 53, wire 419 (S/B) to chassis ground X-939 pin 37, wire 409 (TQ/G) 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3835-ECU Power stages: Throttle valve actuator power stage source 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 (B/Y) to chassis ground X-939 pin 53, wire 419 (S/B) to chassis ground X-939 pin 37, wire 409 (TQ/G) 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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Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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3838-Oxidation catalyst upstream temperature sensor short to high source 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 (N/Y) 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 (N/Y) 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 (N/G) 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 (N/G) and connector X-937 pin 79, wire 323 (N/G). 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 (N/G) to connector X-937 pin 79, wire 323 (N/G). 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 (N/G) and connector X-937 pin 79, wire 323 (N/G). 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 (N/Y) to connector X-937 pin 80, wire 324 (N/Y). 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 (N/Y) and connector X-937 pin 80, wire 324 (N/Y). 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. 84568014 22/03/2013

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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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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3839-Oxidation catalyst upstream temperature sensor short to low source 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 (N/Y) 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 (N/Y) and connector X-937 pin 80, wire 324 (N/Y). 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 (N/G) to connector X-937 pin 79, wire 323 (N/G). 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 (N/G) and connector X-937 pin 79, wire 323 (N/G). 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 (N/Y) to connector X-937 pin 80, wire 324 (N/Y). 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 (N/Y) and connector X-937 pin 80, wire 324 (N/Y). 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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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3840-Diesel particulate filter upstream temperature sensor short to high source 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 (G/W) 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 (G/W) and connector X-937 pin 84, wire 322 (G/W). 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 (B/W) 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 (B/W) and connector X-937 pin 83, wire 320 (B/W). 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 (B/W) to connector X-937 pin 83, wire 320 (B/W). 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 (B/W) and connector X-937 pin 83, wire 320 (B/W). 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 (G/W) to connector X-937 pin 84, wire 322 (G/W). 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 (G/W) and connector X-937 pin 84, wire 322 (G/W). 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. 84568014 22/03/2013

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Wire harnesses - Electrical schematic frame 17 (55.100.DP-C.20.E.17)

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3842-Turbine upstream temperature sensor: Source high for turbine upstream temperature sensor 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 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 (B) and X-937 pin 82, wire 326 (B/W). 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 key switch ON. 84568014 22/03/2013

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(3) Measure the voltage between ECU connector X-937 pin 82, wire 326 (B/W) 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 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.

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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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3843-Turbine upstream temperature sensor: Source low for turbine upstream temperature sensor 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 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 (B/W) to X-937 pin 81, wire 325 (B). 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 key switch OFF. 84568014 22/03/2013

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(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 (B/W) 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 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.

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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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Electrical systems - FAULT CODES

3844-Error state on comparing energizing time to maximum value injector 1 Control Module : ECU Context: This fault has been generated due to the injector 1 programming being incorrect. This failure can be the result of wrong programming / flashing of the ECU or an internal defect of the injector. Using the Electronic Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace the injector.

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3845-Error state on comparing energizing time to maximum value injector 2 Control Module : ECU Context: This fault has been generated due to the injector 2 programming being incorrect. This failure can be the result of wrong programming / flashing of the ECU or an internal defect of the injector. Using the Electronic Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace the injector.

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3846-Error state on comparing energizing time to maximum value injector 3 Control Module : ECU Context: This fault has been generated due to the injector 3 programming being incorrect. This failure can be the result of wrong programming / flashing of the ECU or an internal defect of the injector. Using the Electronic Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace the injector.

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3847-Error state on comparing energizing time to maximum value injector 4 Control Module : ECU Context: This fault has been generated due to the injector 4 programming being incorrect. This failure can be the result of wrong programming / flashing of the ECU or an internal defect of the injector. Using the Electronic Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace the injector.

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3848-Error state on comparing energizing time to minimum value injector 1 Control Module : ECU Context: This fault has been generated due to the injector 1 programming being incorrect. This failure can be the result of wrong programming / flashing of the ECU or an internal defect of the injector. Using the Electronic Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace the injector.

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3849-Error state on comparing energizing time to minimum value injector 2 Control Module : ECU Context: This fault has been generated due to the injector 2 programming being incorrect. This failure can be the result of wrong programming / flashing of the ECU or an internal defect of the injector. Using the Electronic Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace the injector.

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3850-Error state on comparing energizing time to minimum value injector 3 Control Module : ECU Context: This fault has been generated due to the injector 3 programming being incorrect. This failure can be the result of wrong programming / flashing of the ECU or an internal defect of the injector. Using the Electronic Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace the injector.

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3851-Error state on comparing energizing time to minimum value injector 4 Control Module : ECU Context: This fault has been generated due to the injector 4 programming being incorrect. This failure can be the result of wrong programming / flashing of the ECU or an internal defect of the injector. Using the Electronic Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace the injector.

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3852-Lambda (oxygen) sensor: The maximum allowed time for blow out is exceeded 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.

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3870-Timeout for BC2EDC1 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

13 14 16 17

(55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.17)

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3899-Info: Engine temperature exceeded pre-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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Electrical systems - FAULT CODES

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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Electrical systems - FAULT CODES

3906-Injector: Number of injections is limited by quantity balance of high pressure pump Control Module : ECU Context: This fault is caused when the number of desired injections is greater than maximum possible number of injection per work cycle depending on high pressure pump maximum delivery capacity. If this fault has occurred, check for other faults related to rail pressure deviation or fuel delivery. If any of those faults are active, correct those faults to determine if they have corrected this fault. If no other faults are present, check fuel temperature. If temperature is incorrect, allow for machine to rest to ambient temperature. If fuel temperature is good, check the high pressure pump is working correctly. If the high pressure pump is determined to be worn out, replace the high pressure pump.

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Electrical systems - FAULT CODES

3910-Fuel metering unit: Error check for loose contact between metering unit and 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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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

3915-Pressure Relief Valve: Averaged rail pressure is outside the expected range with open PRV Control Module : ECU Context: The engine control unit (ECU) has determined that the Pressure Relief Valve (PRV) is not opening completely, there is a restriction at the PRV connections or a fault is present with the rail pressure sensor or harness. Check for error codes relating to the fuel rail pressure sensor, if other rail pressure sensor errors are present, continue to those tests. If no other rail pressure sensor related error codes are present, remove the PRV valve and check for any damages. If PRV is damaged, replace the valve.

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Electrical systems - FAULT CODES

3916-Pressure Relief Valve: Open time of PRV for wear out monitoring had exceeded maximum value Control Module : ECU Context: The engine control unit (ECU) has detected the rail pressure is not stable. Check for other faults associated with rail pressure. If other faults exist, first correct those faults and then determine if this fault has been corrected. Ensure the pressure relief valve is securely tight.

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Electrical systems - FAULT CODES

3999-Unknown ECM SPN error code 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. Solution: 1. Before proceeding clear the error code with the approved diagnostic equipment. Run the machine under normal conditions and retest. A. If the error code is not indicated, check that the system is operating correctly. B. If the error code is indicated, continue to step 2. 2. Check for other engine related error codes. A. If other engine related error codes are displayed, continue to these tests. B. If no other engine related error codes are displayed, continue to step 3. 3. 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 the power supplies and grounds are 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 Wire Wire Wire

harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

13 14 16 17

(55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14) (55.100.DP-C.20.E.16) (55.100.DP-C.20.E.17)

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1002-Poor or no signal from radar Control Module : XCM (multi-function CM) Possible failure modes: 1. Faulty connectors 2. Fuse F-009 ( 5 A) faulty 3. Radar faulty 4. Wiring fault 5. Control unit ( XCM) fault Solution: 1. Check the connector of the radar X-333, the main cab-transmission connector X-300 and the connector of the control unit ( XCM) 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 (B/Y). 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 ( XCM) X-210. Check between the connector: X-210 pin 19 wire 1.0 (N/Y), and X-333 pin 4 wire 1.0 (N/Y) X-210 pin 33 wire 1.0 (B/W), and X-333 pin 1wire 1.0 (B/W).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 (B) 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 (N/Y)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 (B/Y) and ground. X-333 pin 3 wire 1.0 (B/W) and ground. X-333 pin 4 wire 1.0 (N/Y) 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 ( XCM).

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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-Speed sensor error NO SIGNAL FROM SPEED SENSOR Control Module : XCM (multi-function CM) 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

1005-speed sensor signal too low Control Module : XCM (multi-function CM) 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. IIf no other error codes are displayed,continue to step 2 2. Check the wheel speed sensor. 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 ay 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-Slip Control Potentiometer Voltage Too Low Control Module : XCM (multi-function CM) 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 84 to 14, 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 (U/Y) and ground X-327 pin 5 wire 0.5 (O) 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 (B) and X-327 pin 6 wire 0.5 (B) X-210 pin 7 wire 0.5 (U/Y) and X-327 pin 7 wire 0.5 (U/Y) X-210 pin 17 wire 1.0 (TQ/W) and X-327 pin 5 wire 0.5 (O). 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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Electrical systems - FAULT CODES

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1007-Slip Control Potentiometer Voltage Too High Control Module : XCM (multi-function CM) 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 84 to 14, 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 76. 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 (O) 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 (U/Y) 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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Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

1009-Both external switches operated at the same time Control Module : XCM (multi-function CM) 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 (R/W) and ground X-330 pin 1 wire 0.5 (R/U) and ground X-329 pin 3 wire 0.5 (R/W) and ground X-329 pin 1 wire 0.5 (R/U) 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 (R/U) and X-329 pin 3 wire 0.5 (R/W). 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 (R/U) and X-330 pin 3 wire 0.5 (R/W). If a short circuit is indicated, replace the R/H HPL fender switch. B. If the switch is okay, download the correct level of software. If the fault re--occurs, remove and replace the controller. 84568014 22/03/2013

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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1010-Height Limit Control Potentiometer Voltage Too Low Control Module : XCM (multi-function CM) 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 84 to 14, 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 (S/B) and ground X-327 pin 5 wire 0.5 (O) 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 (B) and X-327 pin 6 wire 0.5 (B) X-210 pin 5 wire 0.5 (S/B) and X-327 pin 3 wire 0.5 (S/B) X-210 pin 17 wire 0.5 (TQ/W) and X-327 pin 5 wire 0.5 (O). 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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Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

1011-Height Limit Control Potentiometer Voltage Too High Control Module : XCM (multi-function CM) 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 84 to 14, 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 (O) 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 (S/B) 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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Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

1012-Drop Rate Control Potentiometer Voltage Too Low Control Module : XCM (multi-function CM) 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 84 to 14, 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 (Y/R) and ground X-327 pin 5 wire 0.5 (O) 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 (1B) and X-327 pin 6 wire 0.5 (B) X-210 pin 4 wire 0.5 (Y/R) and X-327 pin 4 wire 0.5 (Y/R) X-210 pin 17 wire 0.5 (TQ/W) and X-327 pin 5 wire 0.5 (O). 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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Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

1013-Drop Rate Control Potentiometer Voltage Too High Control Module : XCM (multi-function CM) 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 84 to 14, 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 (O) 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 (Y/R) 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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Electrical systems - FAULT CODES

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Electrical systems - FAULT CODES

1014-Right hand load sensing pin - signal too low Control Module : XCM (multi-function CM) 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 approximately 47, 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 approximately 47, 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 (S/TQ) and ground X-332 pin 3 wire 1.0 (1S/G) 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 (B) and X-200 pin 23 wire 1.0 (B). X-332 pin 2 wire 1.0 (S/G) and X-210 pin 9 wire 1.0 (S/G) X-332 pin 3 wire 1.0 (S/TQ) and X-210 pin 25 wire 1.0 (S/U) 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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Electrical systems - FAULT CODES

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55.11 [55.DTC] / 584

Electrical systems - FAULT CODES

1015-Right hand load sensing pin - signal too high Control Module : XCM (multi-function CM) 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 approximately 47, 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 approximately 47, 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 0.5 (B) and ground. X-332 pin 2 wire 1.0 (S/G) and ground. X-332 pin 3 wire 1.0 (S/TQ) 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.

84568014 22/03/2013

55.11 [55.DTC] / 585

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 586

Electrical systems - FAULT CODES

1021-Draft Sensitivity Control Potentiometer Voltage Too Low Control Module : XCM (multi-function CM) 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 84 to 14, 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 (O) and ground X-327 pin 8 wire 0.5 (SR) 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 (B) and X-327 pin 6 wire 0.5 (B) X-210 pin 6 wire 0.5 (R) and X-327 pin 8 wire 0.5 (R) X-210 pin 17 wire 1.0 (TQ/W) and X-327 pin 5 wire 0.5 (O). 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.

84568014 22/03/2013

55.11 [55.DTC] / 587

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 588

Electrical systems - FAULT CODES

1022-Draft Sensitivity Control Potentiometer Voltage Too High Control Module : XCM (multi-function CM) 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 84 to 14, 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 (O) 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 (R) 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.

84568014 22/03/2013

55.11 [55.DTC] / 589

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 590

Electrical systems - FAULT CODES

1023-CONTROL PANEL DISCONNECTED Control Module : XCM (multi-function CM) 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.

84568014 22/03/2013

55.11 [55.DTC] / 591

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 592

Electrical systems - FAULT CODES

1025-Position Control Potentiometer Voltage Too Low Control Module : XCM (multi-function CM) 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 10 to 88, 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 (U/R) and ground X-326 pin C wire 0.5 (O) 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 (U/R) and X-210 pin 3 wire 0.5 (U/R) X-326 pin C wire 0.5 (O) and X-210 pin 17 wire 0.5 (O) X-326 pin D wire 0.5 (B) and X-200 pin 23 wire 1.0 (B). 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.

84568014 22/03/2013

55.11 [55.DTC] / 593

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 594

Electrical systems - FAULT CODES

1026-Position Control Potentiometer Voltage Too High Control Module : XCM (multi-function CM) 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 10 to 88, 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 (O) 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 (U/R) 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.

84568014 22/03/2013

55.11 [55.DTC] / 595

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 596

Electrical systems - FAULT CODES

1027-Lift arm position sensing control voltage low (short or open circuit) Control Module : XCM (multi-function CM) 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 79 to 6, 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 (S/W) and ground X-328 pin 3 wire 1.0 (TQ/W) 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 (B) and X-200 pin 23 wire 1.0 (B) X-328 pin 2 wire 1.0 (S/W) and X-210 pin 2 wire 1.0 (S/W) X-328 pin 3 wire 1.0 (TQ/W) and X-210 pin 17 wire 0.5 (TQ/W). 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.

84568014 22/03/2013

55.11 [55.DTC] / 597

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 598

Electrical systems - FAULT CODES

1030-Signal Ground Open Circuit Control Module : XCM (multi-function CM) 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 (B) and X-326 pin D wire 0.5 (B) X-200 pin 23 wire 1.0 (B) and X-322 pin 1 wire 0.5 (B) X-200 pin 23 wire 1.0 (B) and X-316 pin A wire 1.0 (B) X-200 pin 23 wire 1.0 (B) and X-309 pin 3 wire 1.0 (BR) X-200 pin 23 wire 1.0 (B) and X-328 pin 1 wire 1.0 (B) X-200 pin 23 wire 1.0 (B) and X-327 pin 6 wire 0.5 (B) X-200 pin 23 wire 1.0 (B) and X-332 pin 1 wire 0.5 (BR) X-200 pin 23 wire 1.0 (B) and X-331 pin 1 wire 1.0 (BR) X-200 pin 23 wire 1.0 (B) and X-318 pin 8 wire 1.0 (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 controller.

84568014 22/03/2013

55.11 [55.DTC] / 599

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 600

Electrical systems - FAULT CODES

1032-Draft Control Potentiometer Voltage Too High Control Module : XCM (multi-function CM) 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 14 and 89, 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 (O) 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 (S/B) 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.

84568014 22/03/2013

55.11 [55.DTC] / 601

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 602

Electrical systems - FAULT CODES

1033-Draft Control Potentiometer Voltage Too Low Control Module : XCM (multi-function CM) 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 14 and 89, 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 (S/B) and ground X-326 pin C wire 0.5 (O) 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 (S/B) and X-210 pin 8 wire 0.5 (SB) X-326 pin C wire 0.5 (O) and X-210 pin 17 wire 0.5 (TQ/W) X-326 pin D wire 0.5 (B) and X-200 pin 23 wire 1.0 (B). 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.

84568014 22/03/2013

55.11 [55.DTC] / 603

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 604

Electrical systems - FAULT CODES

1049-Wheel speed sensor open or short circuit Control Module : XCM (multi-function CM) Cause: WHEEL SPEED SENSOR OPEN OR SHORT CIRCUIT Possible failure modes: 1. Faulty connector 2. Faulty wheel speed sensor 3. Wiring harness faulty 4. Faulty controller Solution: 1. 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 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 1, wire 1.0 (W) 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-309 pin 3, wire 1.0 (B) and ground. 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 4. 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 (O/U) and connector X-309 pin 2, wire 1.0 (O/U). 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 connector X-309 pin 2, wire 0.5 (O/U) 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 controller.

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55.11 [55.DTC] / 605

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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55.11 [55.DTC] / 606

Electrical systems - FAULT CODES

1053-5 volt reference shorted to +VE voltage Control Module : XCM (multi-function CM) Cause: CONTROLLER 5 V REFERENCE SHORTED TO POSITIVE VOLTAGE Possible failure modes: 1. Wiring fault 2. Control unit ( XCM) 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 approximately 49, continue to step 3 B. If the value displayed is approximately 49, while still in H9, ch 217 wiggle the harness, the control unit connectors X-200 and X-210, the EDC control panel connector X-326 and X-327 , the connector X-328 of the arm lift potentiometer, X-300 of the transmission--cab main wiring, the shuttle lever connector X-318 , the range and gear lever position sensing button connectors X-301, X-199 and X-308, the clutch pedal potentiometer connector X-322 to check for an intermittent circuit. Channel 217 values will change if an intermittent circuit is detected; Repair or replace as necessary. 3. Check for a short to + 8 V or + 12 V. A. Disconnect the connector of the control unit ( XCM) 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/W) 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 control unit ( XCM).

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55.11 [55.DTC] / 607

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 608

Electrical systems - FAULT CODES

1054-CONTROLLER 5 VOLT REFERENCE SHORT TO GROUND Control Module : XCM (multi-function CM) Possible failure modes: 1. Wiring fault 2. Control unit ( XCM) 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 Channel 217. A. If the value displayed is not approximately 49, continue to step 3 B. If the value displayed is approximately 49, while still in H9, ch 217 wiggle the harness, the control unit connectors X-200 and X-210, the EDC control panel connector X-326 and X-327, the connector X-328 of the arm lift potentiometer, X-300 of the transmission--cab main wiring, the shuttle lever connector X-318, the range and gear lever position sensing button connectors X-301, X-199 and X-308, the clutch pedal potentiometer connector X-322 to check for an intermittent circuit. Channel 217 values will change if an intermittent circuit is detected; Repair or replace as necessary. 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/W) 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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55.11 [55.DTC] / 609

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 610

Electrical systems - FAULT CODES

1057-Module failure Control Module : XCM (multi-function CM) Possible failure modes: 1. Faulty fuse F-009 2. Faulty harness 3. Faulty controller Solution: 1. Check fuse F-009. A. If a fault is indicated with fuse F-009, continue to step 2. B. If the fuse is okay, continue to step 4. 2. Check for a short to ground. A. Disconnect the controller connector X-200. Check between connector X-200 pin 20, wire 1.0 (B/Y) and ground. If a short to ground is indicated, repair or replace the harness as required and replace the fuse. B. If a short to ground is not indicated, continue to step 3. 3. Check for an intermittent short to ground. A. Replace fuse F-009. Connect the controller connector X-200. Turn the Ignition Key Switch ON. Wiggle the harness and connectors to check for an intermittent circuit. Fuse F-009 will blow if an intermittent circuit is detected, repair or replace as required. B. If the error code is still displayed, download the correct level of software. If the fault re-occurs, remove and replace the controller. 4. Check for an open circuit. A. Turn the Ignition Key Switch OFF. Disconnect the controller connectors X-200 and X-220. Check between connector: X-200 pin 20, wire 1.0 (B/Y) and fuse F-009 X-200 pin 19, wire 1.0 (B) and ground X-200 pin 25, wire 1.0 (B) and ground X-200 pin 26, wire 1.0 (B) and ground X-220 pin 21, wire 1.0 (B) and ground X-220 pin 26, wire 1.0 (B) 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 of software. If the fault re-occurs, remove and replace the controller.

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55.11 [55.DTC] / 611

Electrical systems - FAULT CODES

84568014 22/03/2013

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Electrical systems - FAULT CODES

1059-8 volt reference open circuit Control Module : XCM (multi-function CM) Cause: REFERENCE VOLTAGE TO 8 V LOAD SENSING PINS INCORRECT 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 + 8 V sensor supply reference in H9, ch 216. A. If the value displayed is not approximately 79, continue to step 3 B. If the value displayed is approximately 79, while still in H9, ch 216, wiggle the harness, draft pin connector X-331 and X-332, connectors X-200 and X-210 and the transmission -- cab main connector X-300, to check for an intermittent circuit. Channel 216 values will change if an intermittent circuit is detected; Repair or replace as necessary. 3. Check for a short to + 12 V. A. Disconnect the connectors X-331 and X-332 . Turn the ignition key switch ON, check between: X-331 pin 3 wire 1.0 (S/TQ) and ground X-332 pin 3 wire 1.0 (S/TQ) and ground. If a short to + 12 V is detected, turn the ignition key switch OFF. Disconnect the connector of the controller X-210. Turn the ignition key switch ON. If a voltage is still indicated, repair or replace the harness as required. B. If there is no short to + 12 V, continue to step 4 4. Check for a short to ground. A. Check between: X-331 pin 3 wire 1.0 (S/TQ) and ground X-332 pin 3 wire 1.0 (S/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 5 5. Check for open circuit. A. Check between: X-331 pin 3 wire 1.0 (S/TQ) and X-210 pin 25 wire 1.0 (S/U) X-332 pin 3 wire 1.0 (S/TQ) and X-210 pin 25 wire 1.0 (S/U). 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 fault re--occurs, remove and replace controller.

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1067-EDC hydraulic valve supply voltage too low Control Module : XCM (multi-function CM) 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 approximately 42, continue to test for error codes 1063 - EDC Hydraulic Valve Lower Solenoid Open Circuit, 1064 - EDC Hydraulic Valve Raise Solenoid Open Circuit, 1065 - EDC Hydraulic Valve Lower Solenoid Short Circuit, and 1066 - EDC Hydraulic Valve Raise Solenoid Short Circuit. B. If the value displayed is not approximately 42, 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 Fâ&#x20AC;&#x201C;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 (B/Y) and F-009 ( 5 A) wire 1.0 (B/Y). 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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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 03 (55.100.DP-C.20.E.03)

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Electrical systems - FAULT CODES

1068-Height limit calibration error Control Module : XCM (multi-function CM) 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. NOTE: For the calibration procedure, please refer to Electronic module - H1 - Calibration procedures (55.640) in this manual

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2006-Radar no signal fault Control Module : XCM (multi-function CM) Possible failure modes: 1. Faulty connectors 2. Fuse F-009 ( 5 A) faulty 3. Radar faulty 4. Wiring fault 5. Control unit ( XCM) fault Solution: 1. Check the connector of the radar X-333, the main cab-transmission connector X-300 and the connector of the control unit ( XCM) 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 (B/Y). 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 ( XCM) X-210. Check between the connector: X-210 pin 19 wire 1.0 (N/Y), and X-333 pin 4 wire 1.0 (N/Y) X-210 pin 33 wire 1.0 (B/W), and X-333 pin 1wire 1.0 (B/W).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 (B) 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 (N/Y)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 (B/Y) and ground. X-333 pin 3 wire 1.0 (B/W) and ground. X-333 pin 4 wire 1.0 (N/Y) 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 ( XCM).

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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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2011-Clutch pedal potentiometer signal too low Control Module : XCM (multi-function CM) Cause: Short to ground or open circuit between the clutch pedal potentiometer and the control unit ( XCM), 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. Control unit ( XCM) 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 89 and 7, 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 ( XCM) X-230, X-200 and X-210 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-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 (B) and X-200 pin 23, wire 1.0 (B) X-322 pin 2, wire 0.5 (W) and X-230 pin 7, wire 0.5 (W) X-322 pin 3, wire 0.5 (TQ) and X-210 pin 17, 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 with step 5 5. Check for a short to ground. A. Check between the connector: X-322 pin 2, wire 0.5 (W) 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 ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2012-Clutch pedal potentiometer signal too high Control Module : XCM (multi-function CM) Context: Cause: Short to ground or open circuit between the clutch pedal potentiometer and the control unit ( XCM), 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. Control unit ( XCM) 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 89 and 7, 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 ( XCM) 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 (W) and ground X-322 pin 1, wire 0.5 (B) 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) and ground. If the indicated voltage is not approximately + 5 V, repair or replace the harness as required.

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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 (B) 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 ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2014-Voltage from the gear neutral position switch is high Control Module : XCM (multi-function CM) Context: Cause: Short to a voltage between the gear neutral position switch and the control unit ( XCM), or the switch is faulty. Effects: Gear lever neutral position cannot be detected and is assumed to be in gear. A start request will be processed with the shuttle lever, but only if there is no wheel speed sensor error, otherwise the transmission will be disabled. Possible failure modes: 1. Faulty connectors 2. Faulty gear neutral position switch 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the gear neutral switch in H9, Channel 15. A. Operate the gear lever. If the values displayed do not change to approximately 67 in neutral and 30 in gear, continue to step 2 B. If the values displayed are okay, while still in H9 channel 15, wiggle the harness, the gear lever neutral switch connector X-301, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-230 and X-210 to check for an intermittent circuit. Channel 15 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the gear neutral switch connector X-301, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) 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 necessary. B. If the connectors are okay, continue to step 3 3. Check the gear neutral position switch. A. Disconnect the connector X-301. Measure the resistance between: X-301 pin 1 and pin 2. With the gear lever in neutral, should indicate 2760 Ω. X-301 pin 1 and pin 2. With the gear lever in gear, should indicate 560 Ω. If the resistances indicated are not okay, remove and replace the gear neutral position switch. B. If the gear neutral position switch is okay, 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-301 pin 1, wire 1.0 (S) and ground. If 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-301 pin 2, wire 1.0 (TQ/W)) and ground. If the indicated voltage is not approximately + 5 V, repair or replace the harness as required.

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B. If the voltage is approximately + 5 V, download the correct level of software. If the error is repeated, remove and replace the control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

2015-Voltage from the gear neutral position switch is low Control Module : XCM (multi-function CM) Context: Cause: Short to ground between the gear neutral position switch and the control unit ( XCM), or the switch is faulty. Effects: Gear lever neutral position cannot be detected and is assumed to be in gear. A start request will be processed with the shuttle lever, but only if there is no wheel speed sensor error, otherwise the transmission will be disabled. Possible failure modes: 1. Faulty connectors 2. Faulty gear neutral position switch 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the gear neutral switch in H9, Channel 15. A. Operate the gear lever. If the values displayed do not change to approximately 67 in neutral and 30 in gear, continue to step 2 B. If the values displayed are okay, while still in H9 channel 15, wiggle the harness, the gear lever neutral switch connector X-301, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-230 and X-210 to check for an intermittent circuit. Channel 15 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the gear neutral switch connector X-300, the transmission -- cab main connector X-301, and the connectors of the control unit ( XCM) 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 gear neutral position switch. A. Disconnect the connector X-301. Measure the resistance between: X-301 pin 1 and pin 2. With the gear lever in neutral, should indicate 2760 ÎŠ. X-301 pin 1 and pin 2. With the gear lever in gear, should indicate 560 ÎŠ. If the resistances indicated are not okay, remove and replace the gear neutral position switch. B. If the gear neutral position switch is okay, continue to step 4 4. Check for an open circuit. A. Disconnect the connector X-210 and X-230. Check between: X-301 pin 2, wire 1.0 (TQ/W) and X-210 pin 17, wire 1.0 (TQ/W) X-301 pin 1, wire 0.5 (S) and X-230 pin 4, wire 0.5 (S). 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-230 pin 4, wire 0.5 (S) and ground. If a short to ground is indicated, repair or replace the harness as required. 84568014 22/03/2013

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B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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2016-Voltage from the range position switch (R1) is high Control Module : XCM (multi-function CM) Context: Cause: Short to a voltage between the range position switch ( R1) and the control unit ( XCM), or the switch is faulty. Effects: Gear lever range position cannot be detected and is assumed to be in gear. A start request will be processed with the shuttle lever, but only if there is no wheel speed sensor error, otherwise the transmission will be disabled. Possible failure modes: 1. Faulty connectors 2. Faulty range position switch ( R1) 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the range position switch ( R1) in H9, channel 22 A. Operate the range lever. If the values displayed do not change to approximately 67 on engaging range II and III and 30 on engaging I and neutral, continue to step 2 B. If the values displayed are okay, while still in H9 channel 22, wiggle the harness, the range position switch connector ( R1) X-308, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-230 and X-210 and to check for an intermittent circuit. Channel 22 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the range position switch connector ( R1) X-308, in line harness connector X-300, and the connectors of the control unit ( XCM) 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 necessary. B. If the connectors are okay, continue to step 3 3. Check the range position switch ( R1). A. Disconnect the connector X-308. Measure the resistance between: X-308 pin 1 and pin 2. With the gear lever in medium or high range, should indicate 560 ÎŠ. X-308 pin 1 and pin 2. With the gear lever in neutral or low range, should indicate 2760 ÎŠ. If the resistances indicated are not okay, remove and replace the range position switch. B. If the range position switch is okay, continue to step 4 4. Check for a short to positive. A. Turn ignition key switch ON. Measure the voltage between the connector: X-308 pin 1, wire 0.5 (S/R) and ground. If 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-308 pin 2, wire 1.0 (TQ/W) and ground. If the indicated voltage is not approximately + 5 V, repair or replace the harness as required.

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B. If the voltage is approximately + 5 V, download the correct level of software. If the error is repeated, remove and replace the control unit ( XCM).

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Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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2017-Voltage from the range position switch (R1) is low Control Module : XCM (multi-function CM) Context: Cause: Short to ground or open circuit between the range position switch ( R1) and the control unit ( XCM), or the switch is faulty. Effects: Gear lever range position cannot be detected and is assumed to be in gear. A start request will be processed with the shuttle lever, but only if there is no wheel speed sensor error, otherwise the transmission will be disabled. Possible failure modes: 1. Faulty connectors 2. Faulty range position switch ( R1) 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the range position switch ( R1) in H9, channel 22. A. Operate the range lever. If the values displayed do not change to approximately 67 on engaging range II and III and 30 on engaging I and neutral, continue to step 2 B. If the values displayed are okay, while still in H9 channel 22, wiggle the harness, the range position switch connector ( R1) X-308, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-210 and X-230 to check for an intermittent circuit. Channel 22 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the range position switch connector ( R1) X-308, in line harness connector X-300, and the connectors of the control unit ( XCM) 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 range position switch ( R1). A. Disconnect the connector X-308. Measure the resistance between: X-308 pin 1 and pin 2. With the gear lever in medium or high range, should indicate 560 ÎŠ. X-308 pin 1 and pin 2. With the gear lever in neutral or low range, should indicate 2760 ÎŠ. If the resistances indicated are not okay, remove and replace the range position switch. B. If the range position switch is okay, continue to step 4 4. Check for an open circuit. A. Disconnect the connectors X-210 and X-230. Check between: X-308 pin 2, wire 1.0 (TQ/W) and X-210 pin 17, wire 1.0 (TQ/W) X-308 pin 1, wire 0.5 (S/R) and X-230 pin 26, wire 0.5 (S/R). 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-230 pin 26, wire 0.5 (S/R) and ground. 84568014 22/03/2013

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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 control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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2018-Voltage from the range position switch (R2) is high Control Module : XCM (multi-function CM) Context: Cause: Short to a voltage between the range position switch ( R2) and the control unit ( XCM), or the switch is faulty. Effects: Gear lever range position cannot be detected and is assumed to be in gear. A start request will be processed with the shuttle lever, but only if there is no wheel speed sensor error, otherwise the transmission will be disabled. Possible failure modes: 1. Faulty connectors 2. Faulty range position switch ( R2) 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the range position switch ( R2) in H9, channel 23. A. Operate the range lever. If the values displayed do not change to approximately 67 on engaging range I and III and 30 on engaging range II and neutral, continue to step 2 B. If the values displayed are okay, while still in H9 channel 23, wiggle the harness, the range position switch connector ( R2) X-199, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-210 and X-230 to check for an intermittent circuit. Channel 23 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the range position switch connector ( R2) X-199, in line harness connector X-300, and the connectors of the control unit ( XCM) 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 necessary. B. If the connectors are okay, continue to step 3 3. Check the range position switch ( R2). A. Disconnect the connector X-199. Measure the resistance between: X-199 pin 1 and pin 2. With the gear lever in low or high range, should indicate 560 Ω. X-199 pin 1 and pin 2. With the gear lever in neutral or medium range, should indicate 2760 Ω. If the resistances indicated are not okay, remove and replace the range position switch. B. If the range position switch is okay, 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-199 pin 1, wire 0.5 (O) and ground. If 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-199 pin 2, wire 0.5 (TQ/W) and ground. If the indicated voltage is not approximately + 5 V, repair or replace the harness as required.

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B. If the voltage is approximately + 5 V, download the correct level of software. If the error is repeated, remove and replace the control unit ( XCM).

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Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

2019-Voltage from the range position switch (R2) is low Control Module : XCM (multi-function CM) Context: Cause: Short to ground or open circuit between the range position switch ( R2) and the control unit ( XCM), or the switch is faulty. Effects: Gear lever range position cannot be detected and is assumed to be in gear. A start request will be processed with the shuttle lever, but only if there is no wheel speed sensor error, otherwise the transmission will be disabled. Possible failure modes: 1. Faulty connectors 2. Faulty range position switch ( R2) 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the range position switch ( R2) in H9, channel 23. A. Operate the range lever. If the values displayed do not change to approximately 67 on engaging range I and III and 30 on engaging range II and neutral, continue to step 2 B. If the values displayed are okay, while still in H9 channel 23, wiggle the harness, the range position switch connector ( R2) X-199, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-230 and X-210 to check for an intermittent circuit. Channel 23 values will change if an intermittent circuit is detected. Repair or replace as necessary. 2. Check the range position switch connector ( R2) X-199, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) 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 necessary. B. If the connectors are okay, continue to step 3 3. Check the range position switch ( R2). A. Disconnect the connector X-199. Measure the resistance between: X-199 pin 1 and pin 2. With the gear lever in low or high range, should indicate 560 ÎŠ. X-199 pin 1 and pin 2. With the gear lever in neutral or medium range, should indicate 2760 ÎŠ. If the resistances indicated are not okay, remove and replace the range position switch. B. If the range position switch is okay, continue to step 4 4. Check for an open circuit. A. Disconnect the connectors X-230 and X-210. Check between: X-199 pin 2, wire 1.0 (TQ/W) and X-210 pin 17, wire 1.0(TQ/W) X-199 pin 1, wire 0.5 (O) and X-230 pin 5, wire 0.5 (O). 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 connector X-230 pin 5, wire 0.5 (O) and ground. 84568014 22/03/2013

55.11 [55.DTC] / 642

Electrical systems - FAULT CODES

84568014 22/03/2013

55.11 [55.DTC] / 643

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 644

Electrical systems - FAULT CODES

2021-drive line harness disconnected Control Module : XCM (multi-function CM) Context: Transmission disabled. Possible failure modes: 1. Faulty connector 2. Wiring fault Solution: 1. Check the transmission harness 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.

84568014 22/03/2013

55.11 [55.DTC] / 645

Electrical systems - FAULT CODES

2024-All clutches not calibrated Control Module : XCM (multi-function CM) Context: Clutch feathering will be poor, jerky or sluggish. Possible failure modes: 1. Transmission not calibrated 2. Control unit ( XCM) fault Solution: 1. Check whether the transmission has been calibrated. A. If the transmission has not been calibrated since replacing the control unit ( XCM), or since using H8, delete the EEPROM memory and run the transmission calibration procedure. B. If the transmission has been calibrated, download the correct level of the software and run the calibration procedure again. If the error is repeated, remove and replace the control unit ( XCM).

84568014 22/03/2013

55.11 [55.DTC] / 646

Electrical systems - FAULT CODES

2025-Over limit value , Engine speed (rpm) high Control Module : XCM (multi-function CM) Cause: Control unit ( XCM) 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. Control unit ( XCM) 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.

84568014 22/03/2013

55.11 [55.DTC] / 647

Electrical systems - FAULT CODES

2026-Not calibrated , clutch D not calibrated Control Module : XCM (multi-function CM) Context: Effects: Poor performance of the uncalibrated clutch. Possible failure modes: 1. Transmission not calibrated 2. Clutch D solenoid valve fault 3. Hydraulic circuit fault 4. Mechanical failure Solution: 1. Check whether the transmission has been calibrated. A. If the transmission has not been calibrated since replacing the control unit ( XCM), or since using H8, delete the EEPROM memory and run the transmission calibration procedure. B. If the transmission has been calibrated, download the correct level of the software and run the calibration procedure again. If the fault re-occurs again, continue to step 2 2. Check for other error codes being displayed. A. If other error codes are displayed, continue with these tests. B. If no other error code is displayed, continue to step 3 3. Check the solenoid valve of the broken clutch. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, continue to step 4 4. Check the clutch pack pressures. A. If the pressures indicated are approximately 16 bar (232.00 psi), possible mechanical fault within the transmission. If the pressures of all the clutches are low, continue to hydraulic troubleshooting procedures. B. If the pressures indicated are not approximately 16 bar (232.00 psi) on one or more of the clutches there may be an internal leak in the transmission.

84568014 22/03/2013

55.11 [55.DTC] / 648

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 649

Electrical systems - FAULT CODES

2027-Not calibrated , Clutch C not calibrated Control Module : XCM (multi-function CM) Context: Effects: Poor performance of the uncalibrated clutch. Possible failure modes: 1. Transmission not calibrated 2. Clutch C solenoid valve fault 3. Hydraulic circuit fault 4. Mechanical failure Solution: 1. Check whether the transmission has been calibrated. A. If the transmission has not been calibrated since replacing the control unit ( XCM), or since using H8, delete the EEPROM memory and run the transmission calibration procedure. B. If the transmission has been calibrated, download the correct level of the software and run the calibration procedure again. If the fault re-occurs again, continue to step 2 2. Check for other error codes being displayed. A. If other error codes are displayed, continue with these tests. B. If no other error code is displayed, continue to step 3 3. Check the solenoid valve of the broken clutch. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, continue to step 4 4. Check the clutch pack pressures. A. If the pressures indicated are approximately 16 bar (232.00 psi), possible mechanical fault within the transmission. If the pressures of all the clutches are low, continue to hydraulic troubleshooting procedures. B. If the pressures indicated are not approximately 16 bar (232.00 psi) on one or more of the clutches. there may be an internal leak in the transmission.

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55.11 [55.DTC] / 650

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 651

Electrical systems - FAULT CODES

2028-Not calibrated , Clutch B not calibrated Control Module : XCM (multi-function CM) Context: Effects: Poor performance of the uncalibrated clutch. Possible failure modes: 1. Transmission not calibrated 2. Clutch B solenoid valve fault 3. Hydraulic circuit fault 4. Mechanical failure Solution: 1. Check whether the transmission has been calibrated. A. If the transmission has not been calibrated since replacing the control unit ( XCM), or since using H8, delete the EEPROM memory and run the transmission calibration procedure. B. If the transmission has been calibrated, download the correct level of the software and run the calibration procedure again. If the fault re--occurs again, continue to step 2 2. Check for other error codes being displayed. A. If other error codes are displayed, continue with these tests. B. If no other error code is displayed, continue to step 3 3. Check the solenoid valve of the broken clutch. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, continue to step 4 4. Check the clutch pack pressures. A. If the pressures indicated are approximately 16 bar (232.00 psi), possible mechanical fault within the transmission. If the pressures of all the clutches are low, continue to hydraulic troubleshooting procedures. B. If the pressures indicated are not approximately 16 bar (232.00 psi) on one or more of the clutches. there may be an internal leak in the transmission.

84568014 22/03/2013

55.11 [55.DTC] / 652

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 653

Electrical systems - FAULT CODES

2029-Not calibrated , Clutch A not calibrated Control Module : XCM (multi-function CM) Context: Effects: Poor performance of the uncalibrated clutch. Possible failure modes: 1. Transmission not calibrated 2. Clutch A solenoid valve fault 3. Hydraulic circuit fault 4. Mechanical failure Solution: 1. Check whether the transmission has been calibrated. A. If the transmission has not been calibrated since replacing the control unit ( XCM), or since using H8, delete the EEPROM memory and run the transmission calibration procedure. B. If the transmission has been calibrated, download the correct level of the software and run the calibration procedure again. If the fault re--occurs again, continue to step 2 2. Check for other error codes being displayed. A. If other error codes are displayed, continue with these tests. B. If no other error code is displayed, continue to step 3 3. Check the solenoid valve of the broken clutch. A. Remove the solenoid, clean or replace as required. B. If the error code is still displayed, continue to step 4 4. Check the clutch pack pressures. A. If the pressures indicated are approximately 16 bar (232.00 psi), possible mechanical fault within the transmission. If the pressures of all the clutches are low, continue to hydraulic troubleshooting procedures. B. If the pressures indicated are not approximately 16 bar (232.00 psi) on one or more of the clutches. there may be an internal leak in the transmission.

84568014 22/03/2013

55.11 [55.DTC] / 654

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 655

Electrical systems - FAULT CODES

2030-Unidentified failure , Critical code on transmission Control Module : XCM (multi-function CM) Context: Cause: Fault codes for the gear or range lever position sensors and for the speed sensor, clutches engaged at maximum pressure and operator not present. Effects: The transmission is disabled and the red warning light on the dashboard blinks. Possible failure modes: 1. Faults on the gear or range lever position sensors: 2014 - Voltage from the gear neutral position switch is high. 2015 - Voltage from the gear neutral position switch is low. 2016 - Voltage from the range position switch (R1) is high. 2017 - Voltage from the range position switch (R1) is low. 2018 - Voltage from the range position switch (R2) is high. 2019 - Voltage from the range position switch (R2) is low. 2. Faults on the speed sensor: 2049 - Wheel speed sensor voltage too high 2069 - Wheel speed sensor voltage too low 3. The control unit does not see the operator present. Solution: 1. With the resolution of the faults generated with code 2030 (see note in the causes) the fault at issue must be resolved too.

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55.11 [55.DTC] / 656

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 657

Electrical systems - FAULT CODES

2033-Pressure on clutch A would not decrease Control Module : XCM (multi-function CM) Context: Cause: The pressure of clutch A does not drop below 3 bar (43.50 psi) after a change from forward to reverse. Effects: Transmission is disabled. Possible failure modes: 1. Clutch A solenoid valve fault 2. Faulty pressure switch 3. Hydraulic circuit fault 4. Control unit ( XCM) fault Solution: 1. Check for error codes 2041 - Clutch A solenoid valve open circuit or short to ground, 2042 - Clutch A solenoid valve short to +12 V, 2081 - Clutch A safety pressure switch open circuit or short to ground and 2082 - Clutch A safety pressure switch short circuit. 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 2033 - Pressure on clutch A would not decrease is still displayed, continue with step 2 2. Check the clutch solenoid valve connector X-364, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-200 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 3 3. Check the clutch A solenoid. A. Disconnect the connector X-364. If the resistance indicated is not approximately 10 ÎŠ, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 4 4. Check for a short circuit. A. Disconnect the connectors X-200 and X-240. Check between the connector: X-200 pin 4, wire 0.5 (R/G) and X-240 pin 1, wire 1.0 (O/B). If a short circuit is indicated, repair or replace the harness as required. B. If the harness is okay, continue to step 5 5. Check the clutch A solenoid for a mechanical fault. A. If the clutch A solenoid valve is sticking, remove and replace the solenoid assembly. B. If the solenoid valve is okay, continue to step 6 6. Check the hydraulic system pressure. A. If the pressure indicated is approximately 16 bar (232.00 psi), download the correct level of software. If the error is repeated, remove and replace the control unit ( XCM). B. If the pressure indicated is less than approximately 11 bar (159.50 psi), continue with the hydraulic troubleshooting procedure. 84568014 22/03/2013

55.11 [55.DTC] / 658

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 659

Electrical systems - FAULT CODES

2035-Wheel speed too high Control Module : XCM (multi-function CM) 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 wheel speed sensor. 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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55.11 [55.DTC] / 660

Electrical systems - FAULT CODES

2036-Engine speed (rpm) low Control Module : XCM (multi-function CM) NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Cause: The measured ERPM average is 0. 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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55.11 [55.DTC] / 661

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 18 (55.100.DP-C.20.E.18)

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55.11 [55.DTC] / 662

Electrical systems - FAULT CODES

2037-Clutch disconnect switch circuit open Control Module : XCM (multi-function CM) 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 control unit ( XCM), 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. Control unit ( XCM) 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 ( XCM) 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 ( XCM) 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 (U/R) 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: 84568014 22/03/2013

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Electrical systems - FAULT CODES

X-319 pin 4, wire 0.5 (S) and X-318 pin 12, wire 0.5 (S) X-319 pin 3, wire 0.5 (W/U) and X-318 pin 7, wire 0.5 (W/U) X-319 pin 2, wire 0.5 (Y/B) and X-200 pin 8, wire 0.5 (Y/B) 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 ( XCM).

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55.11 [55.DTC] / 664

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 02 (55.100.DP-C.20.E.02) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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55.11 [55.DTC] / 665

Electrical systems - FAULT CODES

2038-Clutch B solenoid valve short to +12 V Control Module : XCM (multi-function CM) Context: Cause: Short circuit to + 12 V between the solenoid valve of clutch B and the control unit ( XCM), or the control unit ( XCM) is faulty. Effects: Transmission is disabled. The tractor is not operative. Possible failure modes: 1. Faulty connectors 2. Wiring fault 3. Control unit ( XCM) fault Solution: 1. Check the clutch B solenoid valve connector X-365, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-200 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 a short to + 12 V. A. Disconnect the connector X-365. Turn the ignition key switch ’ON’. Measure the voltage between connector: X-365 pin 1, wire 1.0 (R) and ground X-365 pin 2, wire 1.0 (B/W) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connectors X-200 and X-240. Turn the ignition key switch ’ON’. If a 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 control unit ( XCM).

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55.11 [55.DTC] / 666

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 667

Electrical systems - FAULT CODES

2039-Clutch B solenoid valve open circuit or short to ground Control Module : XCM (multi-function CM) Context: Cause: Short to ground or open circuit between the clutch B solenoid valve and the control unit ( XCM), or the solenoid valve is faulty. Effects: Clutch B is disabled. Tractor will only drive in forward gears. Possible failure modes: 1. Faulty connectors 2. Clutch B solenoid valve trouble 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the clutch B solenoid valve connector X-365, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-200 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 clutch B solenoid. A. Disconnect the connector X-365. Measure the resistance in the connector: X-365 between pins 1 and 2 If the resistance indicated is not approximately 10 ÎŠ, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 3 3. Check the clutch B solenoid for a short to ground. A. Check 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 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-240. Check between: X-365 pin 1, wire 1.0 (R) and ground X-365 pin 2, wire 1.0 (B/W) 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-365 pin 1, wire 1.0 (R) and X-200 pin 11, wire 1.0 (R) X-365 pin 2, wire 1.0 (B/W) and X-240 pin 2, wire 1.0 (B/W) 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 ( XCM). Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13) 84568014 22/03/2013

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Electrical systems - FAULT CODES

2040-Inconsistent gear lever status switches Control Module : XCM (multi-function CM) Context: Cause: With the machine running, switches R1 and R2 both off for longer than 3 s. Effects: The control unit detects the lever is in neutral even if this has a range engaged, displays the code 2040 and does not disable the transmission. Possible failure modes: 1. Switches faulty 2. Controller ( XCM) fault Solution: 1. Check the other error codes. A. If error codes are displayed, continue to these tests. B. If no other error code is displayed, continue to step 2 2. Check the range switches X-308. and X-199. A. Disconnect the range switch connectors X-308. and X-199. Measure the resistance between: X-308 pin 1 and pin 2. With the R1 switch disengaged, it should indicate 2760 Ω. X-308 pin 1 and pin 2. With the R1 switch engaged, it should indicate 560 Ω. X-199 pin 1 and pin 2. With the R2 switch disengaged, it should indicate 2760 Ω. X-199 pin 1 and pin 2. With the R2 switch engaged, it should indicate 560 Ω. If the resistances indicated are not okay remove and replace the range switch. B. If the range switch es are okay, continue with step 3 3. 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 26, wire 0.5 (O) and ground X-230 pin 5, wire 0.5 (O) and ground If voltage is indicated, repair or replace the harness as required. B. If the harness is okay, repeat the adjustment, described (for the ” Power shuttle 12X12” transmission) and (for the ” Power shuttle transmission with Dual Command ( 2 Speed Power Shift) functions”), or with the diagnostics program: H5 code d170 for R1 and code d169 for R2 H7 channel 2 H9 channel 22 for R1 and channel 23 for R2. C. If the switches are okay, download the correct level of software.

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55.11 [55.DTC] / 669

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 670

Electrical systems - FAULT CODES

2041-Clutch A solenoid valve open circuit or short to ground Control Module : XCM (multi-function CM) Context: Cause: Short to ground or open circuit between the clutch A solenoid valve and the control unit ( XCM), or the solenoid valve is faulty. Effects: Clutch A is disabled. Possible failure modes: 1. Faulty connectors 2. Clutch A solenoid valve trouble 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the clutch A solenoid valve connector X-364, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-200 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 the clutch A solenoid. A. Disconnect the connector X-364. Measure the resistance between the connector: X-364 pin 1 and 2 If the resistance indicated is not approximately 10 ÎŠ, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 3 3. Check the clutch A solenoid for a short to ground. A. Check between the component side of connector: X-364 pin 1 and ground X-364 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 connectors X-200 and X-240. Check between: X-364 pin 1, wire 1.0 (R/G) and ground X-364 pin 2, wire 1.0 (B/O) 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-364 pin 1, wire 1.0 (R/G) and X-200 pin 4, wire 1.0 (R/G) X-364 pin 2, wire 1.0 (B/O) and X-240 pin 1, wire 1.0 (B/O) 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 ( XCM).

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55.11 [55.DTC] / 671

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 672

Electrical systems - FAULT CODES

2042-Clutch A solenoid valve short to +12 V Control Module : XCM (multi-function CM) Context: Cause: Short circuit to 12 V between the solenoid valve of clutch A and the control unit ( XCM), or the control unit ( XCM) is faulty. Effects: Transmission is disabled. The tractor is not operative. Possible failure modes: 1. Faulty connectors 2. Wiring fault 3. Control unit ( XCM) fault Solution: 1. Check the clutch A solenoid valve connector X-364, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-200 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 a short to + 12 V. A. Disconnect X-364. Turn the ignition key switch ’ON’. Measure the voltage between connector: X-364 pin 1, wire 1.0 (R/G) and ground X-364 pin 2, wire 1.0 (B/O) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connectors X-200 and X-240. Turn the ignition key switch ’ON’. If a 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 control unit ( XCM).

84568014 22/03/2013

55.11 [55.DTC] / 673

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 674

Electrical systems - FAULT CODES

2043-Pressure on clutch B would not decrease Control Module : XCM (multi-function CM) Context: Cause: The pressure of clutch B does not drop below 3 bar after a change from reverse to forward. Effects: Transmission is disabled. Possible failure modes: 1. Clutch B solenoid valve trouble 2. Faulty pressure switch 3. Hydraulic circuit trouble 4. Control unit ( XCM) fault Solution: 1. Check for error codes 2038 - Clutch B solenoid valve short to +12 V, 2039 - Clutch B solenoid valve open circuit or short to ground, 2083 - Clutch B safety pressure switch open circuit or short to ground and 2084 - Clutch B safety pressure switch short circuit. 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 2043 is still displayed, continue with step 2 2. Check the clutch B solenoid valve connector X-365, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-200 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 3 3. Check clutch B solenoid. A. Disconnect the connector X-365. Measure the resistance between the connector: X-365 pin 1 and pin 2 If the resistance indicated is not approximately 10 ÎŠ, remove and replace the clutch solenoid valve B. If the resistance is okay, continue to step 4 4. Check for a short circuit. A. Disconnect the connectors X-200 and X-240. Check between the connector: X-200 pin 11, wire 0.5 (R) and X-240 pin 2, wire 1.0 (B/W) If a short circuit is indicated, repair or replace the harness as required. B. If the harness is okay, continue to step 5 5. Check the clutch B solenoid for a mechanical fault. A. If the clutch B solenoid valve is sticking, remove and replace the solenoid assembly. B. If the solenoid is okay, continue to step 6 6. Check the hydraulic system pressure. A. If the pressure indicated is approximately 16 bar (232.00 psi), download the correct level of software. If the error is repeated, remove and replace the control unit ( XCM).

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B. If the pressure indicated is less than approximately 11 bar (159.50 psi), continue with the hydraulic troubleshooting procedure.

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

2047-Clutch disconnect switch set too high Control Module : XCM (multi-function CM) Context: Cause: The error is detected if the clutch pedal position is above 15 %, the shuttle lever is not in neutral and there is no + 12 V at connector X-200 pin 8 for over 1 second. Effects: Tractor drives but has jerky take off. Possible failure modes: 1. Faulty connectors 2. Incorrect clutch pedal potentiometer calibration 3. Incorrect clutch disconnect switch adjustment 4. Clutch disconnect switch faulty 5. Control unit ( XCM) fault Solution: 1. Check for error code 2037 - Clutch disconnect switch circuit open. A. If error code 2037 - Clutch disconnect switch circuit open is displayed, clear the error code and test the system for normal operation. If 2037 - Clutch disconnect switch circuit open is still displayed, continue to this test. B. If the fault is still present, continue with step 2 2. Check the clutch pedal potentiometer in H7 channel 1. A. Cycle clutch pedal. If the values displayed do not change continuously between 0 to 99, perform the clutch potentiometer calibration procedure. B. If the values displayed are okay, continue to step 3 3. Check the clutch disconnect switch adjustment. A. Position the forward/reverse shuttle lever into gear. Depress the clutch pedal. While still in H7, check that the disconnect switch operates between open and closed, indicated by ”O” or ”C”, when the pedal is raised, before 15 %. Adjust the disconnect switch as required. B. If the disconnect switch is adjusted correctly, continue to step 4 4. Check the clutch disconnect switch connector X-319 and the connector of the control unit ( XCM) X-200. 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 5 5. 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, download the correct level of software. If the error is repeated, remove and replace the control unit ( XCM). 84568014 22/03/2013

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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

2048-Clutch disconnect switch set too low Control Module : XCM (multi-function CM) Context: Cause: The error is detected if the clutch pedal position is below 5 % and there is + 12 V at connector X-200 pin 8 for over 1 s. Short to + 12 V between clutch disconnect switch and the control unit ( XCM), or the clutch disconnect switch is faulty or incorrectly adjusted. Effects: Tractor drives but has jerky take off. Possible failure modes: 1. Faulty connectors 2. Incorrect clutch pedal potentiometer calibration 3. Incorrect clutch disconnect switch adjustment 4. Clutch disconnect switch faulty 5. Wiring fault 6. Control unit ( XCM) fault Solution: 1. Check for error code 2037 - Clutch disconnect switch circuit open. A. If error code 2037 - Clutch disconnect switch circuit open is displayed, clear the error code and test the system for normal operation. If 2037 - Clutch disconnect switch circuit open is still displayed, continue to this test. B. If the fault is still present, continue with step 2 2. Check the clutch pedal potentiometer in H7 Channel 1. A. Cycle clutch pedal. If the values displayed do not change continuously between 0 to 99, perform the clutch potentiometer calibration procedure. B. If the values displayed are okay, continue to step 3 3. Check the clutch disconnect switch adjustment. A. Position the forward/reverse shuttle lever into gear. Depress the clutch pedal. While still in H7, check that the disconnect switch operates between open and closed, indicated by ” O” or ” C”, when the pedal is being raised between 5 - 15 %. Adjust the disconnect switch as required. B. If the disconnect switch is adjusted correctly, continue to step 4 4. Check the clutch disconnect switch connector X-319 and the connector of the control unit ( XCM) X-200. 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 5 5. 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.

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Electrical systems - FAULT CODES

B. If the switch is okay, continue with step 6 6. Check for a short to + 12 V. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-319 pin 2, wire 0.5 (Y/B) and ground. If a voltage is indicated, turn the ignition key switch OFF. Disconnect the connector X-200. Turn the ignition key switch ‘ON’. If a 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 control unit ( XCM).

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55.11 [55.DTC] / 681

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

2049-Wheel speed sensor voltage too high Control Module : XCM (multi-function CM) NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal operation. Context: Cause: Short to a positive voltage or an open circuit between the speed sensor and the control unit ( XCM), or the sensor is faulty. Possible failure modes: 1. Faulty connector 2. Faulty speed sensor 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the wheel speed sensor connector X-309, the transmission - cab main connector X-300 and the controller connectors X-200, X-210 and 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-309. Turn the ignition key switch ON. Measure the voltage between connector X-309 pin 1, wire 1.0 (W) 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-309 pin 3, wire 1.0 (B) 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 22, wire 0.5 (O/U) and connector X-309 pin 2, wire 1.0 (O/U). 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-240 pin 22, wire 0.5 (O/U) and ground. If an voltage 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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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2051-Oil temperature sensor - open circuit Control Module : XCM (multi-function CM) Context: Cause: Short to a positive voltage or an open circuit between the oil temperature sensor and the control unit ( XCM), the sensor is faulty, or the oil temperature is below -30 °C (-22.00 °F). Effects: Cold oil temperature is assumed. If the oil is cold, sluggish shifting and a higher than normal clutch pedal bite point will be indicated. Possible failure modes: 1. Oil temperature 2. Faulty connectors 3. Oil temperature sensor faulty 4. Wiring fault 5. Control unit ( XCM) fault Solution: 1. Check the transmission oil temperature sensor in H9, Channel 14. A. The value will change dependant on temperature, at 25 °C (77.0 °F) 52 is displayed; if the reading is incorrect, continue to step 2 B. If the values displayed are okay, while still in H9 channel 14, wiggle the harness, the transmission oil temperature sensor connector X-316, the connectors of the control unit ( XCM) X-200 and X-210 and the transmission -- cab main connector X-300 to check for an intermittent circuit. Channel 14 values will change if an intermittent circuit is detected; Repair or replace as necessary. 2. Check the temperature sensor connector X-316, the connectors of the control unit X-200 and X-210 and in line harness 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 temperature sensor. A. Disconnect the connector X-316. Measure the resistance between the temperature sensor terminals. If the indicated resistance is not between 460 - 540 Ω at 25 °C (77.00 °F), 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 the connectors X-200 and X-210 Check between: X-316 pin B, wire 1.0 (U/R) and X-210 pin 14, wire 0.5 (U/R) X-316 pin A, wire 1.0 (B) and X-200 pin 23, wire 1.0 (B) 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 there is a short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-316 pin B, wire 1.0 (U/R) and ground If a short to positive is indicated, repair or replace the harness as required. 84568014 22/03/2013

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B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2053-5 Volt sensor supply too high Control Module : XCM (multi-function CM) Context: Cause: Short to + 12 V on the + 5 V supply voltage to the switches of the shuttle lever, clutch pedal potentiometer, gear neutral and range, lift arms height potentiometer, lift control panels, PTO ground speed switch and the creeper switch. Effects: Transmission is critically disabled. Possible failure modes: 1. Wiring fault 2. Control unit ( XCM) 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 approximately 49, continue to step 3 B. If the value displayed is approximately 49, while still in H9, ch 217 wiggle the harness and the control unit ( XCM) connector X-210, the EDC control panel connector X-326 and X-327, the connector X-328 of the arm lift potentiometer, X-300 of the transmission-cab main wiring, the shuttle lever connector X-318, the range and gear lever position sensing button connectors X-199, X-301 and X-308, the clutch pedal potentiometer connector X-322, the creeper switch connector X-368 and the ground speed PTO switch connector X-352 to check for an intermittent circuit. Channel 217 values will change if an intermittent circuit is detected; Repair or replace as necessary. 3. Check for a short to + 8 V or + 12 V. A. Disconnect the connector of the control unit ( XCM) X-210. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: X-210 pin 17, wire 0.5 (TQ/W) 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 control unit ( XCM).

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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

03 04 13 14

(55.100.DP-C.20.E.03) (55.100.DP-C.20.E.04) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2054-5 Volt sensor supply too low Control Module : XCM (multi-function CM) Context: Cause: Short to ground or break in the circuit of the + 5 V supply voltage to the switches of the shuttle lever, clutch pedal potentiometer, gear neutral and range, lift arms height potentiometer, lift control panels, PTO ground speed switch and the creeper switch. Effects: Transmission is critically disabled. Possible failure modes: 1. Wiring fault 2. Control unit ( XCM) 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 approximately 49, continue to step 3 B. If the value displayed is approximately 49, while still in H9, ch 217 wiggle the harness and the control unit ( XCM) connector X-210, the EDC control panel connector X-326 and X-327, the connector X-328 of the arm lift potentiometer, X-300 of the transmission-cab main wiring, the shuttle lever connector X-318, the range and gear lever position sensing button connectors X-199, X-301 and X-308, the clutch pedal potentiometer connector X-322, the creeper switch connector X-368 and the ground speed PTO switch connector X-352 to check for an intermittent circuit. Channel 217 values will change if an intermittent circuit is detected; Repair or replace as necessary. 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/W)) 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 error is repeated, remove and replace the control unit ( XCM)..

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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

03 04 13 14

(55.100.DP-C.20.E.03) (55.100.DP-C.20.E.04) (55.100.DP-C.20.E.13) (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2055-Shuttle lever forward switch voltage high Control Module : XCM (multi-function CM) Context: Cause: Short to a positive voltage between the shuttle lever forward switch and the control unit ( XCM), 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. Control unit ( XCM) 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) 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 (W/G) 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 control unit ( XCM).

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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

2056-Shuttle lever forward switch voltage low Control Module : XCM (multi-function CM) Context: Cause: Open circuit or short to ground between the switch of the forward gear, of the shuttle lever and the control unit ( XCM), 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. Control unit ( XCM) 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) 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 control unit ( XCM) X-210. Check in the connector: X-210 between pin 12, wire 0.5 (W/G) and X-318 pin 2, wire 0.5 (W/G) 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 (W/G) 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 control unit ( XCM). 84568014 22/03/2013

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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

2057-Shuttle lever reverse switch voltage high Control Module : XCM (multi-function CM) Context: Cause: Short to a positive voltage between the shuttle lever reverse switch and the control unit ( XCM), 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. Control unit ( XCM) 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) 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 (Y/G) 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 control unit ( XCM).

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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

2058-Shuttle lever reverse switch voltage low Control Module : XCM (multi-function CM) Context: Cause: Open circuit or short to ground between the switch of the reverse gear, of the shuttle lever and the control unit ( XCM), 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. Control unit ( XCM) 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) 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 control unit ( XCM) X-210. Check in the connector: X-210 between pin 13, wire 0.5 (Y/G) and X-318 pin 3, wire 0.5 (Y/G) 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 (Y/G) 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 control unit ( XCM). 84568014 22/03/2013

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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

2059-Shuttle lever switches disagree Control Module : XCM (multi-function CM) Context: Cause: Open circuit between the neutral switch and the control unit ( XCM), or the shuttle lever assembly is faulty. Effects: Transmission is disabled. Possible failure modes: 1. Faulty connectors 2. Faulty shuttle lever assembly 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the other error codes. A. If error codes 2055 - Shuttle lever forward switch voltage high, 2056 - Shuttle lever forward switch voltage low, 2057 - Shuttle lever reverse switch voltage high or 2058 - Shuttle lever reverse switch voltage low are displayed, continue to these tests. B. If no other error code is displayed, continue to step 2 2. Check the shuttle lever connector X-318 and the connector of the control unit ( XCM) 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 3. Check for a short circuit. A. Disconnect the connectors X-318 and X-210. Check between connector: X-318 pin 2, wire 0.5 (W/G) and X-318 pin 3, wire 0.5 (Y/G) If a short circuit is indicated, repair or replace the harness as required. B. If the harness is okay, remove and replace the shuttle lever assembly.

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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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55.11 [55.DTC] / 701

Electrical systems - FAULT CODES

2065-Clutch C solenoid valve open circuit or short to ground Control Module : XCM (multi-function CM) Context: Cause: Short to ground or open circuit between the clutch C solenoid valve and the control unit ( XCM), or the solenoid valve is faulty. Effects: The tractor can be used, but HIGH and LOW cannot be engaged. Possible failure modes: 1. Faulty connectors 2. Clutch C solenoid valve trouble 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the clutch solenoid valve connector X-806, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-200 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 the clutch C solenoid. A. Disconnect the connector X-806. Measure the resistance between the connector: X-806 pin 1 and pin 2 If the resistance indicated is not approximately 10 ÎŠ, remove and replace the clutch solenoid valve. B. If the resistance is okay, continue to step 3 3. Check the clutch C solenoid for a short to ground. A. 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 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-240. Check between: X-806 pin 1, wire 1.0 (L) and ground X-806 pin 2, wire 1.0 (B/Y) 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-806 pin 1, wire 1.0 (L) and X-200 pin 6, wire 1.0 (L) X-806 pin 2, wire 1.0 (B/Y) and X-240 pin 3, wire 1.0 (B/Y) 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 ( XCM). 84568014 22/03/2013

55.11 [55.DTC] / 702

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 703

Electrical systems - FAULT CODES

2066-Clutch D solenoid valve open circuit or short to ground Control Module : XCM (multi-function CM) Context: Cause: Short to ground or open circuit between the clutch D solenoid valve and the control unit ( XCM), or the solenoid valve is faulty. Effects: The tractor can be used, but HIGH and LOW cannot be engaged. Possible failure modes: 1. Faulty connectors 2. Clutch D solenoid valve trouble 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the clutch solenoid valve connector X-807, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-200 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 the clutch D solenoid. A. Disconnect the connector X-807. Measure the resistance between the connector: X-807 between pins 1 and 2 If the resistance indicated is not approximately 10 ÎŠ, remove and replace the clutch solenoid valve. B. remove and replace the clutch solenoid valve. continue to step 3 3. Check the clutch D solenoid for a short to ground. A. 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 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-240. Check between: X-807 pin 1, wire 1.0 (G/W) and ground X-807 pin 2, wire 1.0 (G/B) 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-807 pin 2, wire 1.0 (G/B) and X-240 pin 4, wire 1.0 (G/B) X-807 pin 1, wire 1.0 (G/W) and X-200 pin 7, wire 1.0 (G/W) 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 ( XCM). 84568014 22/03/2013

55.11 [55.DTC] / 704

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 705

Electrical systems - FAULT CODES

2067-Clutch D solenoid valve short to +12 V Control Module : XCM (multi-function CM) Context: Cause: Short circuit to + 12 V between the solenoid valve of clutch D and the control unit ( XCM), or the control unit ( XCM) is faulty. Effects: Transmission is disabled. The tractor is not operative. Possible failure modes: 1. Faulty connectors 2. Wiring fault 3. Control unit ( XCM) fault Solution: 1. Check the clutch D solenoid valve connector X-807, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-200 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 a short to + 12 V. A. Disconnect X-807. Turn the ignition key switch ’ON’. Measure the voltage between connector: X-807 pin 1, wire 1.0 (G/W) and ground X-807 pin 2, wire 1.0 (G/B) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connectors of the control unit ( XCM) X-200 and X-240. Turn the ignition key switch ’ON’. If a 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 control unit ( XCM).

84568014 22/03/2013

55.11 [55.DTC] / 706

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 707

Electrical systems - FAULT CODES

2068-Clutch C solenoid valve short to +12 V Control Module : XCM (multi-function CM) Context: Cause: Short circuit to + 12 V between the solenoid valve of clutch C and the control unit ( XCM), or the control unit ( XCM) is faulty. Effects: Transmission is disabled. The tractor is not operative. Possible failure modes: 1. Faulty connectors 2. Wiring fault 3. Control unit ( XCM) trouble Solution: 1. Check the clutch C solenoid valve connector X-806, the transmission -- cab main connector X-300, and the connectors of the control unit ( XCM) X-200 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 a short to + 12 V. A. Disconnect X-806. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between connector: X-806 pin 2, wire 1.0 (L) and ground X-806 pin 1, wire 1.0 (B/Y) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connectors of the control unit ( XCM) X-200 and X-240. Turn ignition switch to OFF position. If a 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 control unit ( XCM). Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

84568014 22/03/2013

55.11 [55.DTC] / 708

Electrical systems - FAULT CODES

2069-Wheel speed sensor voltage too low Control Module : XCM (multi-function CM) Cause: WHEEL SPEED SENSOR OPEN OR SHORT CIRCUIT Possible failure modes: 1. Faulty connector 2. Faulty wheel speed sensor 3. Wiring harness faulty 4. Faulty controller Solution: 1. 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. 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 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 (W) 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-309 pin 3, wire 1.0 (B) and ground. 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 4. 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 (O/U) and connector X-309 pin 2, wire 1.0 (O/U). 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 connector X-309 pin 2, wire 0.5 (O/U) 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 controller.

84568014 22/03/2013

55.11 [55.DTC] / 709

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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55.11 [55.DTC] / 710

Electrical systems - FAULT CODES

2081-Clutch A safety pressure switch open circuit or short to ground Control Module : XCM (multi-function CM) Context: Cause: Short to ground or open circuit between the clutch A safety pressure switch and the control unit ( XCM), or the pressure switch is faulty. During ignition, when the clutch fluid reaches the pressure switch with a pressure of > 11 bar (159.50 psi), it sends a signal to the control unit ( XCM) to enable clutch engagement. Effects: Pressure information is not available to the control unit ( XCM). The tractor is not operative. Possible failure modes: 1. Faulty connector 2. Fuse F11 ( 5 A) faulty 3. Faulty pressure switch 4. Hydraulic circuit fault 5. Wiring fault 6. Control unit ( XCM) fault Solution: 1. Check the safety pressure switch connectors X-383, X-100, the transmission -- cab main connector X-300, and the connector of the control unit ( XCM) 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 2 2. Check the pressure switch for a closed circuit. A. Disconnect the connectors X-383 and X-100. Check for a closed circuit between the pressure switch terminals. If a closed circuit is not indicated, remove and replace the pressure switch. B. If a closed circuit is indicated, continue to step 3 3. Check the pressure switch for an open circuit. A. Start the engine. Check for an open circuit between the switch terminals. If an open circuit is not indicated, continue to step 4 B. If an open circuit is indicated, continue to step 5 4. Check the hydraulic system pressure. A. If the pressure indicated is approximately 16 bar (232.00 psi), remove and replace the pressure switch. B. If the pressure indicated is less than approximately 11 bar (159.50 psi), continue with the hydraulic troubleshooting procedure. 5. Check fuse F11 ( 5 A). A. Turn the ignition key switch to the â&#x20AC;&#x153;OFFâ&#x20AC;? position. If a fault is indicated with fuse F11 ( 5 A), continue to step 6 B. If the fuse is okay, continue to step 8 6. Check the pressure switch for a short to ground.

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55.11 [55.DTC] / 711

Electrical systems - FAULT CODES

A. Check between each of the switch terminals and ground. If a short to ground is indicated, remove and replace the pressure switch. B. If a short to ground is not indicated, continue to step 7 7. Check for a short to ground. A. Disconnect the connector X-210. Check between: X-383 terminal, wire 1.0 (O/B) and ground X-100 terminal, wire 1.0 (W) 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 control unit ( XCM). 8. Check for + 12 V. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: X-100 terminal, wire 1.0 (W) and ground If the indicated voltage is not approximately + 12 V, repair or replace the harness as required. B. If + 12 V is indicated, continue to step 9 9. Check for an open circuit. A. Turn ignition key switch to OFF position. Disconnect the connector X-210. Check between the connector: X-383 terminal, wire 1.0 (O/B) and X-210 pin 21, wire 0.5 (O/B) 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 ( XCM).

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55.11 [55.DTC] / 712

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 713

Electrical systems - FAULT CODES

2082-Clutch A safety pressure switch short circuit Control Module : XCM (multi-function CM) Context: Cause: Short to a voltage between the clutch A safety pressure switch and the control unit ( XCM), or the pressure switch is faulty. During ignition, when the clutch fluid reaches the pressure switch with a pressure of > 11 bar (159.50 psi), it sends a signal to the control unit ( XCM) to enable clutch engagement. Effects: Pressure information is not available to the control unit ( XCM). The tractor is not operative. Possible failure modes: 1. Faulty connectors 2. Faulty pressure switch 3. Hydraulic circuit fault 4. Wiring fault 5. Control unit ( XCM) fault Solution: 1. Check the safety pressure switch connector X-100 and X-383, the transmission -- cab main connector X-300, and the connector of the control unit ( XCM) X-200. 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 pressure switch for an open circuit. A. Disconnect the connectors X-100 and X-383 . Start the engine. Check for an open circuit between the switch terminals. If an open circuit is not indicated, continue to step 3 B. If an open circuit is indicated, continue to step 4 3. Check the hydraulic system pressure. A. If the pressure indicated is approximately 16 bar (232.00 psi), remove and replace the pressure switch. B. If the pressure indicated is less than approximately 11 bar (159.50 psi), continue with the hydraulic troubleshooting procedure. 4. Check for a short to positive. A. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-383 terminal, wire 1.0 (O/B) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connector X-210. Turn the ignition key switch ’ON’. If a 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 control unit ( XCM).

84568014 22/03/2013

55.11 [55.DTC] / 714

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 715

Electrical systems - FAULT CODES

2083-Clutch B safety pressure switch open circuit or short to ground Control Module : XCM (multi-function CM) Context: Cause: Short to ground or open circuit between the clutch B safety pressure switch and the control unit ( XCM), or the pressure switch is faulty. During ignition, when the clutch fluid reaches the pressure switch with a pressure of > 11 bar (159.50 psi), it sends a signal to the control unit ( XCM) to enable clutch engagement. Effects: Pressure information is not available to the control unit ( XCM). The tractor is not operative. Possible failure modes: 1. Faulty connectors 2. Fuse F11 ( 5 A) faulty 3. Faulty pressure switch 4. Hydraulic circuit fault 5. Wiring fault 6. Control unit ( XCM) fault Solution: 1. Check the safety pressure switch connectors X-522, X-504 , the transmission -- cab main connector X-300, and the connector of the control unit ( XCM) 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 pressure switch for a closed circuit. A. Disconnect the connectors X-522 and X-504. Check for a closed circuit between the pressure switch terminals. If a closed circuit is not indicated, remove and replace the pressure switch. B. If a closed circuit is indicated, continue to step 3 3. Check the pressure switch for an open circuit. A. Start the engine. Check for an open circuit between the switch terminals. If an open circuit is not indicate, continue to step 4 B. If an open circuit is indicated, continue to step 5 4. Check the hydraulic system pressure. A. If the pressure indicated is approximately 16 bar (232.00 psi), remove and replace the pressure switch. B. If the pressure indicated is less than approximately 11 bar (159.50 psi), continue with the hydraulic troubleshooting procedure. 5. Check fuse F11 ( 5 A). A. Turn ignition key switch to OFF position. If a fault is indicated with fuse F11 ( 5 A), continue to step 6 B. If the fuse is okay, continue to step 8 6. Check the pressure switch for a short to ground.

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55.11 [55.DTC] / 716

Electrical systems - FAULT CODES

A. Check between each of the switch terminals and ground. If a short to ground is indicated, remove and replace the pressure switch. B. If a short to ground is not indicated, continue to step 7 7. Check for a short to ground. A. Disconnect the connector X-210. Check between: X-522 terminal, wire 1.0 (O/W) and ground. X-504 terminal, wire 1.0 (W) 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 control unit ( XCM). 8. Check for + 12 V. A. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between the connector: X-504 terminal, wire 1.0 (W) and ground If the indicated voltage is not approximately + 12 V, repair or replace the harness as required. B. If + 12 V is indicated, continue to step 9 9. Check for an open circuit. A. Turn ignition key switch to OFF position. Disconnect the connector X-522. Check between the connector: X-522 terminal, wire 1.0 (O/W) and X-210 pin 28, wire 1.0 (O/W) 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 ( XCM). Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

84568014 22/03/2013

55.11 [55.DTC] / 717

Electrical systems - FAULT CODES

2084-Clutch B safety pressure switch short circuit Control Module : XCM (multi-function CM) Context: Cause: Short to a voltage between the clutch B safety pressure switch and the control unit ( XCM), or the pressure switch is faulty. During ignition, when the clutch fluid reaches the pressure switch with a pressure of > 11 bar (159.50 psi), it sends a signal to the control unit ( XCM) to enable clutch engagement. Effects: Pressure information is not available to the control unit ( XCM). The tractor is not operative. Possible failure modes: 1. Faulty connectors 2. Faulty pressure switch 3. Hydraulic circuit fault 4. Wiring fault 5. Control unit ( XCM) fault Solution: 1. Check the safety pressure switch connectors X-522, X-504 the transmission -- cab main connector X-300, and the connector of the control unit ( XCM) 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 pressure switch for an open circuit. A. Disconnect the connector X-504 and X-522 Start the engine. Check for an open circuit between the switch terminals. If an open circuit is not indicated, continue to step 3 B. If an open circuit is indicated,continue to step 4 3. Check the hydraulic system pressure. A. If the pressure indicated is approximately 16 bar (232.00 psi), remove and replace the pressure switch. B. If the pressure indicated is less than approximately 11 bar (159.50 psi), continue with the hydraulic troubleshooting procedure. 4. Check there is a short to positive. A. Disconnect X-522. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-522 terminal, wire 1.0 (O/W) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connector X-210. Turn the ignition key switch ’ON’. If a 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 control unit ( XCM).

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55.11 [55.DTC] / 718

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 719

Electrical systems - FAULT CODES

2085-No supply to pressure switches for clutch A and B Control Module : XCM (multi-function CM) Context: Cause: The + 12 V supply voltage to the control unit ( XCM) is less than + 6 V at X-230 pin 1. Clutch A and B safety pressure switches not supplied. Effects: The control unit detects no current from the pressure switches of clutches A and B, as a result it considers clutches A and B closed; it ignores this unlikely situation and generates a code that can be displayed even in situations of error code reduction. Possible failure modes: 1. Fuse F-011 ( 5 A) blown. Solution: 1. Check fuse F-011 ( 5 A). A. Replace it. B. If the error is repeated, remove and replace the control unit ( XCM).

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55.11 [55.DTC] / 720

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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55.11 [55.DTC] / 721

Electrical systems - FAULT CODES

2090-Break in CAN communication between the ADIC and the XCM transmission control unit Control Module : XCM (multi-function CM) 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 transmission control unit ( XCM), pin 15 and 16 X-450 from the dashboard control unit ( 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 transmission control unit ( XCM), pin 16, wire 0.75 (G) to the dashboard ( ADIC) X-450 pin 4, wire 0.75 (G) X-200 from the transmission control unit ( XCM), pin 16, wire 0.75 (G) to the diagnostics connector X-376 pin D, wire 0.75 (G) Check continuity on the cable CAN1-A-H. f X-200 from the transmission control unit ( XCM), pin 15, wire 0.75 (Y) to the dashboard ( ADIC) X-450 pin 3, wire 0.75 (Y) X-200 from the transmission control unit ( XCM), pin 15, wire 0.75 (Y) to the diagnostics connector X-376 pin C, wire 0.75 (Y)If the 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 control unit ( XCM) and, if the error is repeated again, fit the control unit back on and replace the dashboard control unit ( ADIC), Wire harnesses - Electrical schematic frame 11 (55.100.DP-C.20.E.11) Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14) Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16) Wire harnesses - Electrical schematic frame 16 (55.100.DP-C.20.E.16)

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55.11 [55.DTC] / 722

Electrical systems - FAULT CODES

2092-Short circuit to + 12V from the clutch cut-out switch Control Module : XCM (multi-function CM) Context: Cause: Short to voltage between the clutch cut-out switch and the control unit ( XCM). Effects: Switch disabled, amber warning light on. Possible failure modes: 1. Wiring fault. 2. Faulty connectors 3. Controller ( XCM) fault Solution: 1. Check the connectors of the control unit ( XCM) X-200 and X-230 and the connector for the push-buttons on the gear lever X-320. 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 a short to positive. A. Disconnect X-320. Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-320 pin 4, wire 1.0 (K/W) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connector X-230. Turn the ignition key switch ’ON’. If a 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 control unit ( XCM).

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55.11 [55.DTC] / 723

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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55.11 [55.DTC] / 724

Electrical systems - FAULT CODES

2093-Short circuit to +12VF to the gear lever switch feed signal Control Module : XCM (multi-function CM) Context: Cause: Short to + 12VF between the control unit ( XCM) and gear lever switches. Effects: Switches disabled, amber warning light on. Possible failure modes: 1. Wiring fault. 2. Faulty connectors 3. Controller ( XCM) trouble Solution: 1. Disconnect the connectors of the control unit ( XCM) X-200 and X-230 and the connector for the push--buttons on the gear lever X-320 . 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 there is a short to + 12VF. A. Disconnect X-320 . Turn the ignition key switch ’ON’. Measure the voltage between the connector: X-320 pin 3, wire 1.0 (N/B) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connector X-200. Turn the ignition key switch ’ON’. If a 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 control unit ( XCM).

84568014 22/03/2013

55.11 [55.DTC] / 725

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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55.11 [55.DTC] / 726

Electrical systems - FAULT CODES

2094-Short circuit to ground to the gear lever switch feed signal Control Module : XCM (multi-function CM) Context: Cause: Short to ground between the control unit ( XCM) and gear lever switches. Effects: Switches disabled, amber warning light on. Possible failure modes: 1. Wiring fault. 2. Faulty connectors 3. Controller ( XCM) fault Solution: 1. Disconnect the connector of the control unit ( XCM) X-200 and X-230 and the connector for the push--buttons on the gear lever X-320 . 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 a short to ground. A. Disconnect X-320. With a tester switched onto measuring continuity, test between connector: X-320 pin 3, wire 1.0 (N/B) and ground If continuity is indicated, disconnect the connector X-200 if continuity is still indicated, repair or replace the harness as required. B. If no continuity is indicated, download the correct level of software. If the error is repeated, remove and replace the control unit ( XCM).

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55.11 [55.DTC] / 727

Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 14 (55.100.DP-C.20.E.14)

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55.11 [55.DTC] / 728

Electrical systems - FAULT CODES

2095-Clutch cut-out button jammed closed Control Module : XCM (multi-function CM) Context: Cause: The control unit ( XCM) detects the clutch cut-out switch has been turned on for a time of 15 s. Effects: The clutch disabling function stays off until the next â&#x20AC;?key OFFâ&#x20AC;? (switching off the machine), the display shows CP and the amber warning light is on. Possible failure modes: 1. Switch faulty. 2. Clutch cut-out switch wiring shorted 3. Controller ( XCM) fault Solution: 1. Check the clutch cut-out switch: A. Disconnect the connector of the clutch cut-out switch X-320. Cycling the switch, test between: X-320 pin 4 and X-320 pin 3 A closed circuit must be indicated with the button pressed, an open circuit with the button released. If the switch operation is not as indicated, remove and replace the clutch cut-out switch. B. If the switch is okay, continue with step 2 2. Check for a short circuit. A. Disconnect the connector of the control unit ( XCM) X-200 and X-230. Check between the connector: X-230 pin 8, wire 1.0 (K/W) and X-200 pin 9, wire 1.0 (N/B) 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 error is repeated, remove and replace the control unit ( XCM).

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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

2097-Short circuit to +12V to the discharge (dump) solenoid valve Control Module : XCM (multi-function CM) Context: Cause: Short circuit to + 12 V between the dump solenoid valve and the control unit ( XCM), or the control unit ( XCM) is faulty. Effects: The transmission is not disabled. The tractor functions and the dashboard turns on the red stop warning light, the error is also visible in fault code reduction mode. Possible failure modes: 1. Faulty connectors 2. Wiring fault 3. Control unit ( XCM) fault Solution: 1. Check the dump solenoid valve connector X-806, the transmission - cab main connector X-300, and the connectors of the control unit ( XCM) X-200 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 a short to + 12 V. A. Disconnect X-806. Turn the ignition key switch â&#x20AC;&#x2122;ONâ&#x20AC;&#x2122;. Measure the voltage between connector: X-806 pin 1, wire 1.0 (G/W) and ground X-806 pin 2, wire 1.0 (G/B) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connector X-200 and X-240. Turn ignition switch to OFF position. If a 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 control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

2098-Short circuit to ground or circuit open to the discharge (dump) solenoid valve Control Module : XCM (multi-function CM) Context: Cause: Short to ground or open circuit between the dump solenoid valve and the control unit ( XCM), or the solenoid valve is faulty. Effects: The tractor transmission is disabled and the dashboard switches on the red stop warning light and emits a critical alarm. Possible failure modes: 1. Faulty connectors 2. Dump solenoid valve fault 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the dump solenoid valve connector X-806, the transmission - cab main connector X-300, and the connectors of the control unit ( XCM) X-200 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. Disconnect the dump solenoid valve connector X-806. Check the dump solenoid. A. Measure the resistance between the connector: X-806, pin 1 and pin 2 If the resistance indicated is not approximately 7.5 ÎŠ, remove and replace the dump solenoid valve. B. If the resistance is okay, continue to step 3 3. Check the dump solenoid valve for short to ground. A. 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 dump solenoid valve. B. If a short to ground is not indicated, continue to step 4 4. Check for a short to ground. A. Check between: X-806 pin 1, wire 1.0 (L) and ground X-806 pin 2, wire 1.0 (B/Y) 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 connectors of the control unit ( XCM) X-200 and X-240. Check between: X-806 pin 2, wire 1.0 (B/Y) and X-240 pin 3, wire 1.0 (B/Y) X-806 pin 1, wire 1.0 (L) and X-200 pin 6, wire 1.0 (L) If an open circuit is indicated, repair or replace the harness as required. 84568014 22/03/2013

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Electrical systems - FAULT CODES

B. If the harness is okay, download the correct level software. If the error is repeated, remove and replace the control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

2110-Shuttle lever neutral switch voltage too low Control Module : XCM (multi-function CM) 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, refer to Electronic module - H5 - Switch operation test (55.640). 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 (O/W) 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/W) 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/W) 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 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2111-Shuttle lever neutral switch voltage too high Control Module : XCM (multi-function CM) 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, refer to Electronic module - H5 - Switch operation test (55.640). 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 (O/W) 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/W) and X-318 pin11 (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 positive. A. Turn the ignition key switch ON. Measure the voltage between connector X-230 pin 13 (TQ/W) 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 14 (55.100.DP-C.20.E.14)

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Electrical systems - FAULT CODES

2419-reactivity switch disagreement Control Module : XCM (multi-function CM) Possible failure modes: 1. Faulty switch 2. Wiring fault 3. Control unit ( XCM) fault Solution: 1. Check for + 12 V A. Turn the Ignition Key Switch ’ON’. Disconnect reactivity switch connector X-313 and measure the voltage between the connector: X-313 pin 2, wire 1.0 (S/U) and ground X-313 pin 3, wire 1.0 (S/U) 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 2 2. Check for an open circuit. A. Turn Ignition Key Switch ‘OFF’. Disconnect the connector of the control unit ( XCM) X-240. Check between the connector: X-313 pin 4, wire 1.0 (S) and X-240 pin 24, wire 1.0 (S) X-313 pin 1, wire 1.0 (S/U) and X-240 pin 33, wire 1.0 (S/U) If an open circuit is indicated, repair or replace the harness as required. B. If an open circuit is not indicate, continue to step 3 3. Check for a short circuit. A. Connect the reactivity switch connector X-313. Check between the connector X-240 pin 33 , wire 1.0 (S/U) and X-240 pin 24, wire 1.0 (S) If a short circuit is indicated, replace the reactivity switch. B. If a short circuit is not indicate, continue to step 4 4. Check for a short to ground. A. Disconnect the reactivity switch connector X-313. Check between the connector: X-313 pin 4, wire 1.0 (S) and ground X-313 pin 1, wire 1.0 (S/U) 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 reactivity switch.If the error is repeated, download the correct level software.

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Electrical systems - FAULT CODES

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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Electrical systems - FAULT CODES

2422-Multicontroller configuration error Control Module : XCM (multi-function CM) Cause: The control unit ( XCM) has detected the presence of a Multicontroller but the option has not been enabled or the Multicontroller has been enabled but the option is not fitted on the machine. Solution: 1. Check that Multicontroller is fitted to the machine and has been enabled. A. Enter the HH MENU programs of the control unit ( ADIC), in RW, H3, Channel 9, select YES to enable the Multicontroller option if fitted or NO to disable if not fitted. NOTE: To enter the HH MENU programs, refer to Electronic module - View HH MENU ACCESS (55.640).

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Electrical systems - FAULT CODES

2429-Creeper switch always on Control Module : XCM (multi-function CM) Possible failure modes: 1. Faulty connector 2. Creeper unit switch faulty 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the creeper unit switch X-368. A. Disconnect the connector X-368. Measure the resistance between: X-368 pin 1 and pin 2. With the lever of the creeper unit disengaged, it should indicate 2760 Ω. X-368 pin 1 and pin 2. With the lever of the creeper unit engaged, it should indicate 560 Ω. If the resistances indicated are not okay remove and replace the range position switch. B. If the creeper unit switch is okay, continue with step 2 2. 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 16, wire 0.5 (S/U) and ground If voltage is indicated, repair or replace the harness as required. B. If the harness is okay, download the correct level of software. If the error is repeated, remove and replace the control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

2430-Creeper unit status switch voltage too low Control Module : XCM (multi-function CM) Context: Cause: Short to ground or open circuit between the creeper unit switch and the control unit ( XCM), or the switch is faulty. Effects: There could be sudden packing of the clutches on moving the shuttle lever. Possible failure modes: 1. Faulty connector 2. Creeper unit switch faulty 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the creeper unit switch X-368 in H9, channel 79. A. If the fast range is engaged, disengage it then operate the creeper unit lever. If the values displayed do not change to approximately 67 on engaging the reduction gear and 30 with the reduction gear disengaged, continue to step 2 B. If the values displayed are okay, while still in H9, channel 79, wiggle the harness, the creeper unit switch X-368, the transmission - cab main connector X-300, and the connectors of the control unit ( XCM) X-230 and X-210 to check for an intermittent circuit. Channel 79 values will change if an intermittent circuit is detected. Repair or replace as required. 2. Check the creeper unit switch X-368, the transmission - cab main connector X-300, and the connectors of the control unit ( XCM) 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 creeper unit switch X-368. A. Disconnect the connector X-368. Measure the resistance between: X-368 pin 1 and pin 2. With the lever of the creeper unit disengaged, it should indicate 2760 ÎŠ. X-368 pin 1 and pin 2. With the lever of the creeper unit engaged, it should indicate 560 ÎŠ. If the resistances indicated are not okay, remove and replace the range position switch. B. If the range position switch is okay, continue to step 4 4. Check for an open circuit. A. Disconnect the connectors X-230 and X-210. Check between: X-368 pin 2, wire 1.0 (TQ/W) and X-210 pin 17, wire 1.0 (TQ/W) X-368 pin 1, wire 0.5 (S/TQ) and X-230 pin 16, wire 0.5 (S/U) 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-230 pin 16, wire 0.5 (S/U) and ground If a short to ground is indicated, repair or replace the harness as required. 84568014 22/03/2013

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Electrical systems - FAULT CODES

B. If the harness is okay, continue to download the correct level of software. If the error is repeated, remove and replace the control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

2431-Creeper unit status switch voltage too high Control Module : XCM (multi-function CM) Context: Cause: Short to a voltage between the creeper unit switch and the control unit ( XCM), or the switch is faulty. Effects: There could be sudden packing of the clutches on moving the shuttle lever. Possible failure modes: 1. Faulty connector 2. Creeper unit switch faulty 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the creeper unit switch X-368 in H9, channel 79. A. If the fast range is engaged, disengage it then operate the creeper unit lever. If the values displayed do not change to approximately 67 on engaging the reduction gear and 30 with the reduction gear disengaged, continue to step 2 B. If the values displayed are okay, while still in H9, channel 79, wiggle the harness, the creeper unit switch X-368, the transmission -cab main connector X-300, and the connectors of the control unit ( XCM) X-230 and X-210 to check for an intermittent circuit. Channel 79 values will change if an intermittent circuit is detected. Repair or replace as required. 2. Check the creeper unit switch X-368, the transmission - cab main connector X-300, and the connectors of the control unit ( XCM) 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 creeper unit switch X-368. A. Disconnect the connector X-368. Measure the resistance between: X-368 pin 1 and pin 2. With the lever of the creeper unit disengaged, it should indicate 2760 Ω. X-368 pin 1 and pin 2. With the lever of the creeper unit engaged, it should indicate 560 Ω. If the resistances indicated are not okay remove and replace the range position switch. B. If the range position 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 16, wire 0.5 (S/U) and ground If 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-368 pin 1, wire 1.0 (S/TQ) and ground If the indicated voltage is not approximately + 5 V, repair or replace the harness as required. 84568014 22/03/2013

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Electrical systems - FAULT CODES

B. If the voltage is approximately + 5 V, download the correct level of software. If the error is repeated, remove and replace the control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

2450-Configuration error Control Module : XCM (multi-function CM) Context: Cause: Incorrect configuration in the H3 program of the control unit ( XCM) RW. Effects: On 20X20 Power Shuttle machines with creeper unit incorrectly configured as: 12X12 Power Shuttle 24X24 Power Shuttle with Dual Command (2 Speed Power Shift) functions if the control unit ( XCM) sees the switch of the creeper unit, in that moment it generates the code. On 24X24 Power Shuttle machines with Dual Command (2 Speed Power Shift) functions incorrectly configured as: 12X12 Power Shuttle 20X20 Power Shuttle with creeper unit if the control unit ( XCM) sees the switch of the HI or LO, in that moment it generates the code. Possible failure modes: 1. Incorrect configuration Solution: 1. Check the configuration in the H3 program of the control unit ( XCM) RJ. A. Enter the diagnostics program HH powering the machine with button 380000843 engaged, select the control unit RW with the buttons for setting minutes m and hours h, enter the control unit diagnostics program by pressing the brightness button. Select the H3 program, with the buttons for setting minutes m and hours h, enter by pressing the brightness button. Select channel ch6, with the buttons for setting minutes m and hours h, enter by pressing the brightness button, select the option, with the minutes m and hours h selection buttons, from between: PS12 -- POWER SHUTTLE PS20 -- POWER SHUTTLE with creeper unit PS24 -- POWER SHUTTLE with Dual Command (2 Speed Power Shift) functions. Pressing the minutes m and hours h selection buttons for one second will sound a beep and the change will be saved, press the brightness button to go back to the H3 program.

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Electrical systems - FAULT CODES

5007-PTO clutch solenoid valve short to + 12V Control Module : XCM (multi-function CM) Cause: Cause: Short circuit to + 12 Volt between the solenoid valve of the PTO clutch and the control unit (XCM), or the control unit (XCM) is faulty. Possible failure modes: 1. Faulty connector 2. PTO clutch solenoid valve faulty 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the PTO clutch solenoid valve connector X-344, the transmission - cab main connector X-300, and the connector of the control unit ( XCM) 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 clutch solenoid valve. A. Disconnect the connector X-344. Measure the resistance the component side of connector: X-344 between pins 1 and 2 If the resistance indicated is not approximately 8 Ω, remove and replace the clutch solenoid valve. B. If the resistance 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 connector: X-344 pin 1, wire 1.0 (N/G) and ground X-344 pin 2, wire 1.0 (B/O) and ground If voltage is indicated, turn OFF the ignition key switch. Disconnect the connector X-240. Turn the ignition key switch ‘ON’. If a 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 control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

5008-PTO clutch solenoid valve open circuit or short to ground Control Module : XCM (multi-function CM) Cause: Short to ground or open circuit between the PTO clutch solenoid valve and the control unit ( XCM), or the solenoid valve is faulty. Possible failure modes: 1. Faulty connectors 2. PTO clutch solenoid valve faulty 3. Wiring fault 4. Control unit ( XCM) fault Solution: 1. Check the PTO clutch solenoid valve connector X-344, the transmission - cab main connector X-300, and the connector of the control unit ( XCM) 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 (N/G) and ground X-344 pin 2, wire 1.0 (B/O) 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 (N/G) and X-240 pin 18, wire 1.0 (N/G) X-344 pin 2, wire 1.0 (B/O) and X-240 pin 14, wire 1.0 (B/O) 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 ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

5027-PTO speed sensor open circuit or short circuit to VBAT Control Module : XCM (multi-function CM) 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. Control unit ( XCM) fault Solution: 1. Check the rear PTO speed sensor connector X-341, the transmission - cab main connector X-300 and the connector of the control unit ( XCM) 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 (S/U) 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 (B) 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 (N/W) and connector X-341 pin 2, wire 1.0 (N/W). 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 (N/W) 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 control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

5034-Rear PTO fender switch - open circuit/short to ground Control Module : XCM (multi-function CM) Context: Effects: PTO disabled. With the key ON and pressing the PTO fender switch(es) the transmission control unit ( XCM) signals a fault: Possible failure modes: 1. Faulty PTO fender switch(es) 2. Wiring fault 3. Control unit ( XCM) fault Solution: 1. Check 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 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 (S/U) there is a voltage of + 12 V. Check that there is no continuity between: X-349 on pin 2, wire 0.5 (N/B) and X-347 on pin 1, wire 0.5 (S/U). B. If this condition is met pass on to step 4, otherwise repair the wiring or, if necessary, replace the fuse F010 ( 5 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 (N/B) and ground X-230 pin 21, wire 0.5 (O) 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 (N/B) and X-349 pin 2, wire 0.5 (N/B) X-230 pin 21, wire 0.5 (O) and X-349 pin 3, wire 0.5 (O) X-230 pin 21, wire 0.5 (O) and X-347 pin 3, wire 0.5 (O) 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 ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

5037-Cab rear PTO switch jammed on (normally off) Control Module : XCM (multi-function CM) Context: Effects: PTO disabled. Possible failure modes: 1. Faulty PTO switch 2. Wiring fault 3. Control unit ( XCM) 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 control unit ( XCM) X-240. Check between the connector: X-350 pin 3, wire 0.5 (S) and X-350 pin 2, wire 0.5 (N/L) 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 (N/L) 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 control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

5043-Rear PTO fender switch stuck on Control Module : XCM (multi-function CM) Context: Effects: PTO disabled. Possible failure modes: 1. Faulty PTO fender switch(es) 2. Wiring fault 3. Control unit ( XCM) 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 RW 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 ( XCM) 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 (N/B) and ground X-349 pin 3, wire 0.5 (O) and ground 84568014 22/03/2013

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Electrical systems - FAULT CODES

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 control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

5044-PTO speed sensor short circuit to ground Control Module : XCM (multi-function CM) 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. Control unit ( XCM) fault Solution: 1. Check the rear PTO speed sensor connector X-341, the transmission - cab main connector X-300 and the connector of the control unit ( XCM) 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 (S/U) 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 (B) 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 (N/W) and connector X-341 pin 2, wire 1.0 (N/W). 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 (N/W) 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 (N/W) and X-341 pin 3, wire 1.0 (B). 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 control unit ( XCM). 84568014 22/03/2013

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

5045-Ground speed PTO switch open/short to GND Control Module : XCM (multi-function CM) Possible failure modes: 1. Faulty ground speed PTO switch 2. Wiring fault 3. Control unit ( XCM) 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 67 on engaging the switch and 30 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 control unit ( XCM) 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 control unit ( XCM) 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/W) and ground If approximately + 5 Vis 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/W) and X-210 pin 17, wire 1.0 (TQ/W) X-352 pin 2, wire .1.0 (G) and X-230 pin 17, wire 1.0 (G) 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 1.0 (G) and ground If a short to ground is indicated, repair or replace the harness as required. 84568014 22/03/2013

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Electrical systems - FAULT CODES

B. If the harness is okay, continue to download the correct level of software. If the error is repeated, remove and replace the control unit ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04) Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

5046-Ground speed PTO switch short to 12V Control Module : XCM (multi-function CM) Context: Cause: Short to a voltage between the ground speed PTO switch and the control unit ( XCM), or the switch is faulty.

Possible failure modes: 1. Faulty ground speed PTO switch 2. Wiring fault 3. Control unit ( XCM) 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 67 on engaging the switch and 30 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 control unit ( XCM) 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 control unit ( XCM) 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 1.0 (G) 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/W) 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 control unit ( XCM). 84568014 22/03/2013

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04) Wire harnesses - Electrical schematic frame 13 (55.100.DP-C.20.E.13)

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Electrical systems - FAULT CODES

5047-Ground speed PTO configuration error Control Module : XCM (multi-function CM) Cause: The control unit ( XCM) 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 RW, 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 Electronic module - View HH MENU ACCESS (55.640).

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Electrical systems - FAULT CODES

5098-Rear PTO fender switch option not enabled Control Module : XCM (multi-function CM) Cause: The control unit ( XCM) 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 RW, H3, Channel 3, select YES to enable the rear PTO fender switches. NOTE: To enter the HH MENU programs, refer to Electronic module - View HH MENU ACCESS (55.640).

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Electrical systems - FAULT CODES

6023-Four-wheel drive clutch solenoid valve open circuit or short to ground Control Module : XCM (multi-function CM) Cause: Short to ground or open circuit between the four-wheel drive clutch solenoid valve and the control unit ( XCM), or the solenoid valve is faulty. Possible failure modes: 1. Faulty connectors 2. Four-wheel drive clutch solenoid valve faulty 3. Wiring fault 4. Control unit ( XCM) 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 ( XCM) 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: X-342 between pins 1 and 2 If the resistance indicated is not approximately 8 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 (U/G) 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 (U/G) and X-240 pin 17, wire 1.0 (U/G) X-342 pin 2, wire 1.0 (B) 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 ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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Electrical systems - FAULT CODES

7017-Differential lock solenoid valve open circuit or short to ground Control Module : XCM (multi-function CM) Cause: Short to ground or open circuit between the differential lock solenoid valve and the control unit ( XCM), or the solenoid valve is faulty. Possible failure modes: 1. Faulty connectors 2. Differential lock solenoid valve faulty 3. Wiring fault 4. Control unit ( XCM) 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 ( XCM) 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: X-343 between pins 1 and 2 If the resistance indicated is not approximately 8 ÎŠ, 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 (Y) 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 (Y) and X-240 pin 9, wire 0.5 (Y) X-343 pin 2, wire 1.0 (B) 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 ( XCM).

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Electrical systems - FAULT CODES

Wire harnesses - Electrical schematic frame 04 (55.100.DP-C.20.E.04)

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Index Electrical systems - 55 FAULT CODES - DTC 1002-Poor or no signal from radar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564 1003-Speed sensor error NO SIGNAL FROM SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567 1004-Wheel Speed Sensor Signal Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1005-speed sensor signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568 1006-Slip Control Potentiometer Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569 1007-Slip Control Potentiometer Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571 1008-Raise / Work Switch Failure (Command Arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1009-Both external switches operated at the same time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573 1010-Height Limit Control Potentiometer Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575 1011-Height Limit Control Potentiometer Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577 1012-Drop Rate Control Potentiometer Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579 1013-Drop Rate Control Potentiometer Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581 1014-Right hand load sensing pin - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583 1015-Right hand load sensing pin - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585 1017-Left Hand Load Sensing Pin Signal Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1018-Both Load Sensing Pins Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1019-Load Sensing Pin 8V Reference Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1020-Load Sensing Pin 8V Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1021-Draft Sensitivity Control Potentiometer Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587 1022-Draft Sensitivity Control Potentiometer Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589 1023-CONTROL PANEL DISCONNECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591 1024-Perform The Hydraulic Lift Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1025-Position Control Potentiometer Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593 1026-Position Control Potentiometer Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595 1027-Lift arm position sensing control voltage low (short or open circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597 1028-Lift Arm Position Sensing Control Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1029-Hydraulic Control Valve Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1030-Signal Ground Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599 1031-Chassis Harness Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 1032-Draft Control Potentiometer Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 1033-Draft Control Potentiometer Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603 1049-Wheel speed sensor open or short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605 1053-5 volt reference shorted to +VE voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607 1054-CONTROLLER 5 VOLT REFERENCE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609

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1057-Module failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611 1059-8 volt reference open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613 1063-EDC Hydraulic Valve Lower Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1064-EDC Hydraulic Valve Raise Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 1065-EDC Hydraulic Valve Lower Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 1066-EDC Hydraulic Valve Raise Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 1067-EDC hydraulic valve supply voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615 1068-Height limit calibration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617 1070-Electronic Draft Control (EDC) - ram configuration not set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 14015-5V supply voltage - too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 14016-5V supply voltage - too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 14021-Cranking line - shorted to +12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 14022-Cranking line - shorted to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 14051-Fuel tank level sender open circuit or short to high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 14052-Fuel tank level sender short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 14058-Seat Switch Closed for Over 25 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 14093-Seat switch signal short to + 12V or open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 14094-Seat switch signal short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 14100-Pneumatic brake pressure sensor detected but not configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 14107-Front hitch present but not configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 14108-Rear PTO sensor present but not configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 14109-EDC present but not configured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 14200-Battery isolator switch closed to battery at Key ON for more than 30 seconds . . . . . . . . . . . . . . . . . . . . . . 102 14900-Control unit (XCM) disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 14901-Engine controller missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 2006-Radar no signal fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618 2011-Clutch pedal potentiometer signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621 2012-Clutch pedal potentiometer signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 2014-Voltage from the gear neutral position switch is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627 2015-Voltage from the gear neutral position switch is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630 2016-Voltage from the range position switch (R1) is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633 2017-Voltage from the range position switch (R1) is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636 2018-Voltage from the range position switch (R2) is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639 2019-Voltage from the range position switch (R2) is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642 2021-drive line harness disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645 2024-All clutches not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646 2025-Over limit value , Engine speed (rpm) high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647 2026-Not calibrated , clutch D not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648 2027-Not calibrated , Clutch C not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650 2028-Not calibrated , Clutch B not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652 2029-Not calibrated , Clutch A not calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654 2030-Unidentified failure , Critical code on transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656

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2033-Pressure on clutch A would not decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658 2035-Wheel speed too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660 2036-Engine speed (rpm) low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661 2037-Clutch disconnect switch circuit open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663 2038-Clutch B solenoid valve short to +12 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666 2039-Clutch B solenoid valve open circuit or short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668 2040-Inconsistent gear lever status switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669 2041-Clutch A solenoid valve open circuit or short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671 2042-Clutch A solenoid valve short to +12 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673 2043-Pressure on clutch B would not decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675 2047-Clutch disconnect switch set too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678 2048-Clutch disconnect switch set too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680 2049-Wheel speed sensor voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683 2051-Oil temperature sensor - open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685 2052-Oil Temperature Sensor - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 2053-5 Volt sensor supply too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 688 2054-5 Volt sensor supply too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 690 2055-Shuttle lever forward switch voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692 2056-Shuttle lever forward switch voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694 2057-Shuttle lever reverse switch voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696 2058-Shuttle lever reverse switch voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698 2059-Shuttle lever switches disagree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 2065-Clutch C solenoid valve open circuit or short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702 2066-Clutch D solenoid valve open circuit or short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704 2067-Clutch D solenoid valve short to +12 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706 2068-Clutch C solenoid valve short to +12 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708 2069-Wheel speed sensor voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709 2081-Clutch A safety pressure switch open circuit or short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711 2082-Clutch A safety pressure switch short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714 2083-Clutch B safety pressure switch open circuit or short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716 2084-Clutch B safety pressure switch short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718 2085-No supply to pressure switches for clutch A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 2090-Break in CAN communication between the ADIC and the XCM transmission control unit . . . . . . . . . . . . . . 722 2092-Short circuit to + 12V from the clutch cut-out switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 2093-Short circuit to +12VF to the gear lever switch feed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 2094-Short circuit to ground to the gear lever switch feed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727 2095-Clutch cut-out button jammed closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729 2097-Short circuit to +12V to the discharge (dump) solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731 2098-Short circuit to ground or circuit open to the discharge (dump) solenoid valve . . . . . . . . . . . . . . . . . . . . . . . 733 2110-Shuttle lever neutral switch voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 736 2111-Shuttle lever neutral switch voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738 2419-reactivity switch disagreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740

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2422-Multicontroller configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742 2429-Creeper switch always on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743 2430-Creeper unit status switch voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745 2431-Creeper unit status switch voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 748 2450-Configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751 3001-Foot throttle sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 3002-Foot throttle sensor - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 3003-Foot throttle sensor - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 3006-Coolant temperature signal - signal not plausible (compared with engine oil temperature) . . . . . . . . . . . . . 121 3007-Coolant temperature sensor - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 3008-Coolant temperature signal - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 3010-Boost temperature sensor - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 3011-Boost temperature sensor - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 3015-Fuel temperature sensor - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 3016-Fuel temperature sensor - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 3019-Boost pressure sensor - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 3024-Atmospheric pressure sensor - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 3025-Atmospheric pressure sensor - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 3027-Oil pressure sensor: Defect fault check for plausibility from digital sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 3037-Boost pressure sensor - signal low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 3051-Battery voltage to ECU - voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 3052-Battery voltage to ECU - voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 3059-ECU main relay: Stuck main relay error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 3063-Cylinder1 - injector cable short circuit (high side to ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 3071-Cylinder 3 - injector cable short circuit (high side to ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 3079-Cylinder 2 - injector cable short circuit (high side to ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 3083-Cylinder 4 - injector cable short circuit (high side to ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 3088-Crankshaft sensor - no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 3089-Crankshaft sensor - invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 3090-Camshaft sensor - no signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 3091-Camshaft sensor - invalid signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 3093-Offset between camshaft and crankshaft - outside boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 3096-ECM Busoff on vehicle CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 3102-Rail pressure sensor CP3 - signal below range min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 3104-Rail pressure relief valve - open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 3105-Rail pressure relief valve - pressure shock requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 3106-Pressure relief valve reached maximum allowed opening count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 3107-Fuel metering unit - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 3108-Fuel metering unit - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 3112-Rail pressure sensor CP3 - signal above range maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 3126-Hand throttle - channel 1 signal above range max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 3127-Hand throttle - channel 1 signal below range min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

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3137-Metering unit - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 3139-Metering unit signal range check - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 3140-Metering unit signal range check - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 3141-Fuel flow setpoint too low - fuel metering unit: leakage is detected based on fuel quantity balance . . . . . 203 3146-Water sensor in the fuel filter : Water in fuel level sensor defect detection . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 3157-Engine control unit (ECU) not detected on the CANbus or the engine dataset registration information was not available from the engine within the time required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 3158-Invalid ECM checksum (the engine dataset does not match the dataset registered for this machine. Register the new dataset if the dataset has just been updated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 3166-Fuel filter heater relay - short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 3167-Fuel filter heater relay - short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 3168-Fuel filter heater relay - no load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 3169-Fuel filter heater relay - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 3176-Fuel metering unit: Set point of metering unit in overrun mode not plausible . . . . . . . . . . . . . . . . . . . . . . . . . 217 3177-Engine overspeed detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 3179-Timeout of CAN message BC2EDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 3180-Timeout of CAN message VCM2EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 3188-Injector cylinder 1 warning - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 3192-Injector cylinder 2 warning - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 3196-Injector cylinder 3 warning - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 3200-Injector cylinder 4 warning - open load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 3210-Bank 1 - general short circuit on injection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 3218-Bank 2 - general short circuit on injection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 3230-Injection processor (CY33X) error - SPI communication failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 3235-Number of injections limited - by charge balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 3236-Number of injections limited - by quantity balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 3237-Number of injections limited - by software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 3238-ECU power stages: Errors of the power failure detection of CY320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 3239-Engine controller EEPROM - read operation failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 3240-Engine controller EEPROM - write operation failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 3241-Engine controller EEPROM - read/write error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 3242-ECU internal: Visibility of software resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 3243-ECU internal: Visibility of software resets in DSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 3244-ECU recovery (visible) - recovery occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 3245-ECM processor - watchdog not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 3252-Controller watchdog - SPI communication failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 3253-Analog digital converter (ADC) : Diagnostic fault check to report the error in voltage ratio in ADC monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 3255-Analog digital converter (ADC) : Diagnostic fault check to report the ADC test error . . . . . . . . . . . . . . . . . . 257 3256-Analog Digital Converter (ADC) : Diagnostic fault check to report the NTP error in ADC monitoring . . . . 258 3265-Overrun monitoring - injection time too long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 3266-Engine speed : Diagnostic fault check to report the engine speed error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 3283-Sensor supply voltage 2 - high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

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3285-Sensor supply voltage 3 - high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 3293-Fuel Metering Unit: maximum positive deviation of rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 3301-Fuel metering unit: Maximum negative rail pressure deviation with metering unit on lower limit is exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 3305-Fuel metering unit: Minimum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 3309-Fuel metering unit: Maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 3334-Timeout of CAN message TSC1-PE torque (when active) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 3335-Timeout of CAN message TSC1-PE torque (when inactive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 3338-Timeout of CAN message TSC1-VE speed (when inactive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 3339-Timeout of CAN message TSC1-VE speed (when active) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 3358-CAN transmit timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 3361-ECM EEPROM - general error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 3362-Torque to quantity map - not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 3368-Info: Torque limitation due to OBD performance limiter by legislation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 3374-Injection quantity adjustment failure - invalid EEPROM adjustment value checksum . . . . . . . . . . . . . . . . . . 281 3402-Rail pressure sensor: Maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 3405-ECU Power stages: Open load temperature error on the turbocharger PWM output power stage . . . . . . 283 3406-ECU Power stages: Over temperature error on the Turbocharger PWM output power stage . . . . . . . . . . . . 44 3408-Lambda sensor: Oxygen concentration implausibly high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 3409-Oil pressure switch: Oil pressure too low (at engine running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 3410-Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 3411-Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 3414-Short circuit in glow plug 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 3415-Short circuit in glow plug 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 3416-Short circuit in glow plug 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 3417-Short circuit in glow plug 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 3418-ECU power stages: short circuit to battery error on the turbocharger PWM output power stage . . . . . . . . 304 3419-ECU power stages: Short circuit to ground error on the turbocharger PWM output power stage . . . . . . . 307 3420-CAN Bus received frames: DFC of auxiliary engine shutdown switch message . . . . . . . . . . . . . . . . . . . . . . 310 3425-Turbocharger: Over boost deviation at P2 too high in pressure charger regulator . . . . . . . . . . . . . . . . . . . . 311 3427-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter low . . . . . . . . . . 313 3428-Diesel particulate filter pressure sensor: Not plausibility error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 3429-Diesel particulate filter pressure sensor: Hoseline plausibility error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 3430-EGR inducement less severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 3431-EGR Inducement most severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 3433-Diesel particulate filter (DPF) inducement less severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 3434-Diesel particulate filter (DPF) inducement most severe derating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 3517-Ambient air temperature sensor - signal too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 3518-Ambient air temperature sensor - signal too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 3616-Torque limitation due to turbo charger protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 3648-Turbocharger: P2 pressure errors in PCR - pressure deviation too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 3650-Battery voltage: Source high for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

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3651-Battery voltage: Source low for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 3652-CAN Bus: Bus off of CAN node A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 3655-Torque limitation, engine protection: General report of the event of torque limitations . . . . . . . . . . . . . . . . . 333 3656-Torque limitation, engine protection: Torque limitation caused by particulate filter . . . . . . . . . . . . . . . . . . . . 334 3657-CAN Bus Received frames: Timeout error of CAN receive-frame CM1BC . . . . . . . . . . . . . . . . . . . . . . . . . . 335 3663-EGR command saturation over higher threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 3664-EGR command saturation over lower threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 3665-Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 3666-Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 3667-Open load error for power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 3668-Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 3669-Short circuit to battery on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 3670-Short circuit to battery on Out2 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 3671-Short circuit to ground on Out1 error for H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 3672-Short circuit to ground on Out2 error for H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 3673-Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 3674-Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 3675-Long time EGR valve drift at closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 3676-EGR valve position sensor voltage source high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366 3677-EGR valve position sensor voltage source low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 3680-Injection cut off: Injection cut off demand for shut off coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372 3688-Water sensor in the fuel filter: WIF sensor check is failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373 3689-DFC for faulty diagnostic data transmission or protocol error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375 3691-No load error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378 3692-Over temperature error on ECU power stage for glow plug low voltage system . . . . . . . . . . . . . . . . . . . . . . 380 3693-Short circuit to battery error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383 3694-Short circuit to ground error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 3699-EEPROM: Error in EEPROM block EEPData1, SD correction can not be calculated . . . . . . . . . . . . . . . . . . 47 3702-Injection control: Detection of failed engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389 3703-Injection control: Check of minimum rail pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 3704-Injector adjustment programming: Check of missing injector adjustment value programming . . . . . . . . . . 391 3705-Injector adjustment programming: Check of missing injector adjustment value programming . . . . . . . . . . 392 3706-Injector adjustment programming: Check of missing injector adjustment value programming . . . . . . . . . . 393 3707-Lambda sensor: Open circuit at the lambda sensor Nernst cell pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394 3708-Lambda sensor: Open circuit at the lambda sensor pump current pin - IP (lambda = 1 detection) . . . . . . 397 3709-Lambda sensor: Open circuit at the lambda sensor virtual ground pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 3710-Lambda sensor: Fault to indicate dynamics of the sensor signal too small . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 3711-SCB error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 3712-Lambda sensor: SCG error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 3713-Lambda sensor: Open load error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406 3714-Lambda sensor: Fault code to indicate source high error for O2 calibration . . . . . . . . . . . . . . . . . . . . . . . . . 408 3715-Lambda sensor: Fault code to indicate source low error for O2 calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 411

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3716-Lambda sensor: O2 value above the max threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 3720-Lambda sensor: Low battery voltage at the SPI chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416 3721-Lambda sensor: Fault check to indicate SPI chip error of lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 3722-Lambda sensor temperature Ri exceeds the maximum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418 3723-Lambda sensor temperature Ri is below the minimum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 3724-Lambda sensor: Short to battery at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422 3725-Lambda sensor: Short to ground at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 3727-Info: Low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426 3728-Info: Too low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 3735-Fuel metering unit: Over temperature of device driver of metering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 3736-Lambda sensor: O2 concentration is outside the predefined window during heater coupling detection . . 430 3737-Lambda sensor: Over temperature error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431 3738-Analog digital convertor (ADC): Diagnostic fault check to report multiple errors while checking the complete ROM-memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433 3739-Power stages, injector: Loss of synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 3740-Power stages, injector: DFC to set a torque limitation once an error is detected before MoCSOP's error reaction is set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435 3741-Power stages, injector: Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 3742-Power stages, injector: Too many SPI errors during MoCSOP execution . . . . . . . . . . . . . . . . . . . . . . . . . . . 437 3743-Power stages, injector: Diagnostic fault check to report the error in under voltage monitoring . . . . . . . . . . 438 3744-Power stages, injector: Diagnostic fault check to report the error in over voltage monitoring . . . . . . . . . . . 439 3745-Power stages, injector: Diagnostic fault check to report that WDA is not working correctly . . . . . . . . . . . . 440 3746-Power stages, injector: OS timeout in the shut off path test. Failure setting the alarm task period . . . . . . 441 3747-Power stages, injector: Diagnostic fault check to report that the positive test failed . . . . . . . . . . . . . . . . . . . 442 3748-Power stages, injector: Diagnostic fault check to report the timeout in the shut off path test . . . . . . . . . . . 443 3750-Injection control: Error in the plausibility of the injection energizing time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 3751-Injection control: Error in the plausibility of the start of energizing angles . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 3752-Zero Fuel Calibration (ZFC): Error in the plausibility of the energizing times of the zero fuel quantity calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446 3753-Level 2 monitoring: Diagnostic fault check to report the error due to injection quantity correction . . . . . . . 447 3754-Level 2 monitoring: Diagnostic fault check to report the plausibility error in rail pressure monitoring . . . . 448 3755-Level 2 monitoring: Diagnostic fault check to report the error due to torque comparison . . . . . . . . . . . . . . 449 3756-Level 2 monitoring: Diagnosis fault check to report the demand for normal mode due to an error in the post injection 2 quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 3757-Level 2 monitoring: Diagnosis fault check to report the error to demand for an ICO due to an error in the post injection 2 shut off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 3758-Level 2 monitoring: Diagnosis fault check to report the error to demand for an ICO due to an error in the post injection 3 efficiency factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452 3759-Level 2 monitoring: Diagnosis of curr path limitation forced by ECU monitoring level 2 . . . . . . . . . . . . . . . . 453 3760-Level 2 monitoring: Diagnosis air path limitation due to a functional control unit monitoring forced by ECU monitoring level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 3761-Level 2 monitoring: Diagnosis quantity path limitation due to a functional control unit monitoring (level 2) 455 3762-Level 2 monitoring: Reported overvoltage of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456 3763-Level 2 monitoring: Reported under voltage of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458

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3764-Main relay: Early opening defect of main relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 3766-Diesel particulate filter pressure sensor: Fault check for the pressure sensor plausibility . . . . . . . . . . . . . . . 55 3767-ECU internal: Diagnostic fault check to report 'WDA active' due to errors in query/response communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463 3768-ECU internal: Diagnostic fault check to report 'ABE active' due to under voltage detection . . . . . . . . . . . . 464 3769-ECU internal: Diagnostic fault check to report 'ABE active' due to overvoltage detection . . . . . . . . . . . . . . 465 3770-ECU internal: Diagnostic fault check to report 'WDA/ABE active' due to unknown reason . . . . . . . . . . . . . 466 3773-Turbocharger: Under boost detected in pressure charger regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467 3786-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter - high . . . . . . . . 469 3787-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter - very high . . . . 470 3789-Regeneration duration exceeds maximum allowed duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471 3790-Diesel particulate filter (DPF): Signal range check flow resistance of the particulate filter - maximum . . . 472 3794-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor . . . 475 3795-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor . . . 478 3796-Diesel particulate filter pressure sensor hose line error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 3797-Diesel particulate filter pressure sensor: SRC high for PFlt differential pressure sensor . . . . . . . . . . . . . . . 481 3798-Diesel particulate filter pressure sensor: SRC low for PFlt differential pressure sensor . . . . . . . . . . . . . . . . 484 3799-Pressure relief valve: Pressure relief valve is forced to open, perform pressure shock . . . . . . . . . . . . . . . . 487 3800-Pressure relief valve: Quantity balance check if a successful PRV opening is ensured . . . . . . . . . . . . . . . 488 3801-Turbine upstream pressure sensor: Source high for turbine upstream pressure sensor . . . . . . . . . . . . . . . 489 3802-Turbine upstream pressure sensor: Source low for turbine upstream pressure sensor . . . . . . . . . . . . . . . . 492 3803-ECU internal: Error on R2S2 module (low level chip driver for the power stage chips) . . . . . . . . . . . . . . . . 495 3808-Fuel metering unit: set point of metering unit not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496 3810-Fuel pressure sensor: rail pressure raw value is intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497 3811-ECU sensor supply monitor: ECU internal: Error sensor supplies 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499 3812-Physical range check high for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 3813-Physical range check low for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501 3814-ECU temperature sensor: SPI Error ECU temperature sensor (LM71) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502 3818-Open load error for power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503 3819-Over current error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506 3820-Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509 3821-Short circuit to battery on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512 3822-Short circuit to battery on Out2 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514 3823-Short circuit to ground on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516 3824-Short circuit to ground on Out2 error for H-Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519 3825-Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 3826-Temperature dependent over current error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522 3827-Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525 3834-ECU Power stages: Throttle valve actuator power stage source high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526 3835-ECU Power stages: Throttle valve actuator power stage source low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528 3838-Oxidation catalyst upstream temperature sensor short to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530 3839-Oxidation catalyst upstream temperature sensor short to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533

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55.11 [55.DTC] / 786

3840-Diesel particulate filter upstream temperature sensor short to high source . . . . . . . . . . . . . . . . . . . . . . . . . . 535 3841-Diesel particulate filter upstream temperature sensor shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . 60 3842-Turbine upstream temperature sensor: Source high for turbine upstream temperature sensor . . . . . . . . . 538 3843-Turbine upstream temperature sensor: Source low for turbine upstream temperature sensor . . . . . . . . . . 541 3844-Error state on comparing energizing time to maximum value injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544 3845-Error state on comparing energizing time to maximum value injector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545 3846-Error state on comparing energizing time to maximum value injector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546 3847-Error state on comparing energizing time to maximum value injector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547 3848-Error state on comparing energizing time to minimum value injector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548 3849-Error state on comparing energizing time to minimum value injector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549 3850-Error state on comparing energizing time to minimum value injector 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 3851-Error state on comparing energizing time to minimum value injector 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551 3852-Lambda (oxygen) sensor: The maximum allowed time for blow out is exceeded . . . . . . . . . . . . . . . . . . . . . 552 3870-Timeout for BC2EDC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553 3899-Info: Engine temperature exceeded pre-warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555 3900-Info: Engine temperature exceeded warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556 3906-Injector: Number of injections is limited by quantity balance of high pressure pump . . . . . . . . . . . . . . . . . . 557 3910-Fuel metering unit: Error check for loose contact between metering unit and ECU . . . . . . . . . . . . . . . . . . . 558 3915-Pressure Relief Valve: Averaged rail pressure is outside the expected range with open PRV . . . . . . . . . . 560 3916-Pressure Relief Valve: Open time of PRV for wear out monitoring had exceeded maximum value . . . . . . 561 3999-Unknown ECM SPN error code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562 5007-PTO clutch solenoid valve short to + 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 752 5008-PTO clutch solenoid valve open circuit or short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754 5027-PTO speed sensor open circuit or short circuit to VBAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756 5033-Rear PTO Cab Normally Closed Switch Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 5034-Rear PTO fender switch - open circuit/short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758 5035-Rear PTO Fender Switch Input Short To 12V+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 5037-Cab rear PTO switch jammed on (normally off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 760 5043-Rear PTO fender switch stuck on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 762 5044-PTO speed sensor short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765 5045-Ground speed PTO switch open/short to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 767 5046-Ground speed PTO switch short to 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 770 5047-Ground speed PTO configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 772 5098-Rear PTO fender switch option not enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 773 6023-Four-wheel drive clutch solenoid valve open circuit or short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 774 7017-Differential lock solenoid valve open circuit or short to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776 CH-HOT OIL WARNING: displayed above 100 degrees C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 CL-COLD OIL WARNING: displayed below 20 degrees C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 U17-Seat switch not activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 U18-Correct start up procedure not used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 U19-Oil temperature < 10 Â°C, calibration is not possible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 U20-Parking brake not applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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U21-ERPM is below 1250, increase throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 U22-ERPM is above 1350, reduce throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 U23-Shuttle lever is in neutral, shift lever to forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 U24-Incorrect range selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 U25-Main gear lever is in neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 U26-Clutch pedal is not up, release clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 U31-Wheel speed sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 U36-Calibration value too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 U37-Calibration value too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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

84568014 22/03/2013 EN

SERVICE MANUAL Platform, cab, bodywork, and decals

T5.105 T5.115 T5.95

84568014 22/03/2013

Contents Platform, cab, bodywork, and decals - 90

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 T5.105 , T5.115 , T5.95

[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 T5.105 , T5.115 , T5.95

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Platform, cab, bodywork, and decals - 90 Cab - 150

T5.105 T5.115 T5.95

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90.1 [90.150] / 1

Contents Platform, cab, bodywork, and decals - 90 Cab - 150

SERVICE Cab and platform Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Platform, cab, bodywork, and decals - Cab

Cab and platform - Remove 1.

free the bottom steps of the right-hand ladder with the retainer (1) , raise it, with the knob (2) , take off the battery cover, detach the battery electric cable.

SEZ21CAP4A-7

WLAPL4S90C111A

WLAPL4S90C112A

Remove the hood as described in the operation Hood - Remove (90.100)

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.

WLAPL4S90C109A

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.

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Platform, cab, bodywork, and decals - Cab

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

WLAPL4S90C113A

WLAPL4S90C114A

WLAPL4S90C115A

WLAPL4S90C116A

Detach the pipe fixing bracket (1) , the delivery piping (2) and return piping (3) to the cab heater.

Drain the fuel tank by removing the bottom drain plug.

Unscrew the fixing bolts (1) and remove the righthand steps (2) . Carry out the same operation for the leftâ&#x2C6;&#x2019;hand steps.

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Platform, cab, bodywork, and decals - Cab

10.

Remove the glove compartment. 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) , if fitted.

WLAPL4S90C117A

11.

12.

13.

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.

WLAPL4S90C118A

WLAPL4S90C119A

WLAPL4S90C120A

Mark and detach the gear and range control tie-rods (1) and the handbrake tie-rod (2) .

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

14.

15.

16.

17.

On the rear left-hand side of the transmission disconnect the power take−off gearbox cable, where applicable.

WLAPL4S90C121A

WLAPL4S90C122A

WLAPL4S90C123A

WLAPL4S90C124A

On the left of the transmission, in the direction of the synchronized power take−off lever, disconnect the cable of the synchronized power take−off lever, where applicable.

Detach the tie-rods (1) from the rear spool valves.

Detach the brake pipeline (1) from the right-hand reduction unit box. Carry out the same operation on the left-hand side. Put caps on the pipelines to prevent leakage of brake fluid.

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Platform, cab, bodywork, and decals - Cab

18.

19.

20.

21.

Disconnect the straps retaining the exhaust device and remove it from the muffler

WLAPL4S90C125A

WLAPL4S90C126A

WLAPL4S90C127A

WLAPL4S90C128A

Disconnect the two connections of the cab wiring harness (1) .

From the back, disconnect the connection of the cabtransmission wiring harness (1) , the splitter connector of the third spool valve (2) , the cab-transmission ground cable and the Italian version trailer brake cable if fitted.

Position tool (1) inside the cab, hitch to a hoist using ropes and lightly take up the slack.

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Platform, cab, bodywork, and decals - Cab

22.

23.

24.

Unscrew the bottom nut (1) of the cab right-hand rear fixing screw. Carry out the same operation on the other side.

WLAPL4S90C129A

WLAPL4S90C130A

WLAPL4S90C131A

Unscrew the relevant fixing screws, detach the footrest (1) , lift the front part of the mat (2) and unscrew the cab front fixing nut. Do this on both sides.

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 and platform - Install 1.

Pick up the cab 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.

Tighten the cab fixing screws to a torque of 200 NÂˇm (147.51 lb ft) (20,4 kgm) keeping to the following tightening sequence.

NOTE: Cab fixing nut tightening sequence. 1st phase: right-hand front nut; 2nd phase: left-hand rear nut 3rd phase: left-hand front nut 4rd phase: right-hand rear nut 3.

Remove the cab lifting tool, working from inside the cab and detach it from the hoist.

Reconnect the oil delivery pipe to the power steering.

Join the two connectors of the cab wiring harness to the engine wiring harness

Reconnect the transmission wiring and cab ground, the third spool valve splitter cable and the Italian trailer brake cable, if applicable.

Connect the rear spool valve control tie-rods.

Refit the exhaust pipe and tighten the relevant retaining strap.

Reconnect the brake pipes to the reduction unit and bleed the braking circuit.

10.

Reconnect the air-conditioning pipes

11.

Reconnect the ventral spool valve joystick tie-rods.

12.

Reconnect the gear and range control tie-rods, taking care to reconnect the right tie-rods to their linkages as marked during disassembly.

13.

Reconnect the pipes to the power steering cylinder .

14.

Refit the bottom guard of the fuel tank, rest the tank and secure it with the relevant straps. Reconnect the fuel pipes as marked during disassembly. Fill the tank.

15.

Fit on the two ladders and secure them by means of the relevant bolts.

16.

Reconnect the two pipelines to the cab heater, and refit the relevant pipe retaining bracket.

17.

Refill the radiator with engine coolant.

18.

Recharge the air-conditioning system via the control unit.

19.

Refit the two side panels covering the engine and the relevant fixing bolts.

20.

Raise the rear of the tractor with a hydraulic jack, fit the two rear wheels back on and tighten the fixing nuts. Lower the machine back down.

21.

Fit the front mudguards back on (if applicable). 84568014 22/03/2013

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Platform, cab, bodywork, and decals - Cab

22.

Fit the hood back on.

23.

Reconnect the battery negative cable.

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Index Platform, cab, bodywork, and decals - 90 Cab - 150 Cab and platform - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cab and platform - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

T5.105 T5.115 T5.95

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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 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Remove 1.

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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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Install 1.

Insert the lifting sling on the hood.

Reconnect the rear support hinging the bonnet and tighten the four fixing screws

Reconnect the gas cylinder for raising the hood and refit the retaining clip.

Reconnect the front lights cable connection 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 Hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

84568014 22/03/2013 EN

SPECIAL TOOL INDEX Genuine 380000315 [Recovery And Rrecharge Portable System (For Discharging And Recovering Of The Refrigerant)] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 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)] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 380000301 [Rotating Engine Stand] 50006 [Punch] 50144 [Tool To Make For Bevel Pinion Extraction] 380000301 [Rotating Engine Stand] 380000291 [PShift & PShuttle Clutch Piston Return Spring Compressor] 380000290 [Transmission Clutch A-B Drum Seal Installer] 380000296 [PShift &PShuttle Drive Shaft Seal Installer] 380000258 [Handgrip ] 380000289 [Limp Home Device] 380000843 [Diagnostic Test Switch]

Reference

PAGE

Engine - Remove

10.1 / 6

Engine - Remove

10.1 / 13

Engine - Remove

10.1 / 13

Engine - Install

10.1 / 16

Engine - Install

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Engine - Install

10.1 / 17

Engine - Install

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Engine - Install

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Engine - Install

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Engine - Install

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Transmission drive housing - Remove

21.1 / 9

Transmission drive housing - Remove

21.1 / 10

Transmission drive housing - Remove

21.1 / 11

Transmission drive housing - Install

21.1 / 12

Transmission drive housing - Install

21.1 / 12

Transmission drive housing - Disassemble

21.1 / 17

Transmission drive housing - Disassemble Transmission drive housing - Disassemble

21.1 / 20 21.1 / 21

Power shuttle transmission - Special tools

21.2 / 6

Power shuttle transmission - Special tools

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Power shuttle transmission - Special tools

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Power shuttle transmission - Special tools Power shuttle transmission - Special tools

21.2 / 6 21.2 / 6

Power shuttle transmission - Special tools

21.2 / 6

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Genuine 50169 [Front Axle Drive Cover Removal And Reassembly Tool. ] 50223 [Guide Pin] 380000301 [Rotating Engine Stand] 380000291 [PShift & PShuttle Clutch Piston Return Spring Compressor] 380000290 [Transmission Clutch A-B Drum Seal Installer] 380000296 [PShift &PShuttle Drive Shaft Seal Installer] 380000258 [Handgrip ] 380000243 [Transmission Clutch Spring Compressor] 380000244 [Transmission Shaft Support/Retainer] 380000245 [Transmission Clutch Drum Seal Installer] 380000289 [Limp Home Device] 50169 [Front Axle Drive Cover Removal And Reassembly Tool. ] 50223 [Guide Pin] 380000301 [Rotating Engine Stand] 380000291 [PShift & PShuttle Clutch Piston Return Spring Compressor] 380000290 [Transmission Clutch A-B Drum Seal Installer] 380000296 [PShift &PShuttle Drive Shaft Seal Installer] 380000258 [Handgrip ] 380000289 [Limp Home Device] 380000843 [Diagnostic Test Switch] 50169 [Front Axle Drive Cover Removal And Reassembly Tool. ] 50223 [Guide Pin] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 380000569 [Tractor Separation Trolley] 380000301 [Rotating Engine Stand] 380000291 [PShift & PShuttle Clutch Piston Return Spring Compressor] 380000290 [Transmission Clutch A-B Drum Seal Installer]

Reference

PAGE

Power shuttle transmission - Special tools

21.2 / 7

Power shuttle transmission - Special tools Power shuttle transmission - Special tools

21.2 / 7 21.2 / 11

Power shuttle transmission - Special tools

21.2 / 11

Power shuttle transmission - Special tools

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Power shuttle transmission - Special tools

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Power shuttle transmission - Special tools Power shuttle transmission - Special tools

21.2 / 11 21.2 / 11

Power shuttle transmission - Special tools

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Power shuttle transmission - Special tools

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Power shuttle transmission - Special tools

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Power shuttle transmission - Special tools Power shuttle transmission - Special tools

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Power shuttle transmission - Special tools

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Power shuttle transmission - Special tools Power shuttle transmission - Special tools

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Power shuttle transmission - Special tools

21.2 / 16

Power shuttle transmission - Special tools

21.2 / 17

Power shuttle transmission - Special tools Transmission housing - Remove

21.2 / 17 21.2 / 63

Transmission housing - Remove

21.2 / 64

Transmission housing - Install

21.2 / 65

Transmission housing - Install

21.2 / 65

Clutch - Disassemble Clutch casing with power shuttle

21.6 / 13

Clutch - Disassemble Clutch A.

21.6 / 20

Clutch - Disassemble Clutch A.

21.6 / 21

84568014 22/03/2013

Genuine 380000290 [Transmission Clutch A-B Drum Seal Installer] 380000290 [Transmission Clutch A-B Drum Seal Installer] 380000291 [PShift & PShuttle Clutch Piston Return Spring Compressor] 380000301 [Rotating Engine Stand] 380000244 [Transmission Shaft Support/Retainer] 380000244 [Transmission Shaft Support/Retainer] 380000244 [Transmission Shaft Support/Retainer] 380000244 [Transmission Shaft Support/Retainer] 380000291 [PShift & PShuttle Clutch Piston Return Spring Compressor] 380000290 [Transmission Clutch A-B Drum Seal Installer] 380000290 [Transmission Clutch A-B Drum Seal Installer] 380000290 [Transmission Clutch A-B Drum Seal Installer] 380000291 [PShift & PShuttle Clutch Piston Return Spring Compressor] 380000301 [Rotating Engine Stand] 380000243 [Transmission Clutch Spring Compressor] 380000243 [Transmission Clutch Spring Compressor] 380000245 [Transmission Clutch Drum Seal Installer] 380000245 [Transmission Clutch Drum Seal Installer] 380000243 [Transmission Clutch Spring Compressor] 50007 [Tool To Make For Adjusting The Gearbox Driving Shaft Bearings] 50007 [Tool To Make For Adjusting The Gearbox Driving Shaft Bearings] 50007 [Tool To Make For Adjusting The Gearbox Driving Shaft Bearings] 380000279 [Seal Installer Tool For 50mm Piston Seal] 380000280 [Seal Installer Tool For 35mm Piston Seal] 380000285 [MFD Drive Shaft Seal Installer] 50107 [Adapter]

Reference

PAGE

Clutch - Disassemble Clutch A.

21.6 / 21

Clutch - Disassemble Clutch A.

21.6 / 21

Clutch - Assemble Clutch A

21.6 / 22

Clutch - Disassemble Clutch casing with Power Shuttle and Dual Command Clutch - Disassemble Clutch casing with Power Shuttle and Dual Command Clutch - Disassemble Clutch casing with Power Shuttle and Dual Command Clutch - Assemble Clutch casing with Power Shuttle and Dual Command Clutch - Assemble Clutch casing with Power Shuttle and Dual Command Clutch - Disassemble Clutch A of Dual command

21.6 / 27

Clutch - Assemble Clutch A of Dual command

21.6 / 39

Clutch - Assemble Clutch A of Dual command

21.6 / 39

Clutch - Assemble Clutch A of Dual command

21.6 / 39

Clutch - Assemble Clutch A of Dual command

21.6 / 40

Clutch - Disassemble Clutch casing with power shuttle and creeper unit Transmission drive and driven shafts - Disassemble

21.6 / 44

Transmission drive and driven shafts - Disassemble

21.6 / 54

Transmission drive and driven shafts - Assemble

21.6 / 55

Transmission drive and driven shafts - Assemble

21.6 / 55

Transmission drive and driven shafts - Assemble

21.6 / 55

Transmission drive and driven shafts - Adjust

21.6 / 56

Transmission drive and driven shafts - Adjust

21.6 / 56

Transmission drive and driven shafts - Adjust

21.6 / 56

Electro-hydraulic control - Special tools

23.1 / 3

Electro-hydraulic control - Special tools

23.1 / 3

Electro-hydraulic control - Special tools

23.1 / 3

Electro-hydraulic control - Special tools

23.1 / 3

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21.6 / 30 21.6 / 30 21.6 / 34 21.6 / 34 21.6 / 36

21.6 / 54

Genuine 380000280 [Seal Installer Tool For 35mm Piston Seal] 380000279 [Seal Installer Tool For 50mm Piston Seal] 50107 [Adapter] 380000268 [Bevel Pinion Ring Nut Wrench] 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] 380000269 [Wheel Hub Bearing Ring Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000252 [Front Axle Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000255 [Differential Overhaul Support] 380000251 [Front Axle Overhaul Stand] 380000251 [Front Axle Overhaul Stand]

Reference

PAGE

Front-Wheel Drive

23.1 / 11

Front-Wheel Drive

23.1 / 11

Front-Wheel Drive Powered front axle - Special tools

23.1 / 14 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 / 6

Powered front axle - Special tools

25.1 / 6

Powered front axle - Special tools

25.1 / 6

Powered front axle - Special tools

25.1 / 6

Powered front axle - Special tools

25.1 / 6

Powered front axle - Special tools

25.1 / 6

Powered front axle - Special tools

25.1 / 6

Powered front axle - Special tools

25.1 / 6

Powered front axle - Special tools

25.1 / 6

Powered front axle - Special tools

25.1 / 6

Four-Wheel Drive

25.1 / 22

Four-Wheel Drive

25.1 / 22

Four-Wheel Drive

25.1 / 25

Four-Wheel Drive

25.1 / 29

Four-Wheel Drive

25.1 / 29

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

Bevel gear set and differential carrier - Adjust

25.2 / 13

Bevel gear set and differential carrier - Adjust

25.2 / 14

Differential lock Multi-plate clutch - Overhaul

25.2 / 20

Planetary drive and hub - Disassemble

25.3 / 5

Planetary drive and hub - Disassemble

25.3 / 5

84568014 22/03/2013

Genuine 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] 380000235 [Swivel Housing Torque Check Adapter] 380000235 [Swivel Housing Torque Check Adapter] 380200018 [Sunken seal Key on Spindle (with brakes)] 380200018 [Sunken seal Key on Spindle (with brakes)] 380200018 [Sunken seal Key on Spindle (with brakes)] 380000227 [Axle Housing And Differential Unit Lifting Hook] 380000301 [Rotating Engine Stand] 380000249 [Universal Pinion Installation Tool Kit] 380000250 [Differential Lock Fork Spring Installer] 380000240 [Hydraulic Pressure Test Kit] 50041 [Differential Block Sleeve Adjuster] 50164 [Guide Pin Set (No. 2)] 50006 [Punch] 50007 [Tool To Make For Adjusting The Gearbox Driving Shaft Bearings] 50169 [Front Axle Drive Cover Removal And Reassembly Tool. ] 50144 [Tool To Make For Bevel Pinion Extraction] 50027 [Tool To Make For Adjusting The Bevel Drive] 50027 [Tool To Make For Adjusting The Bevel Drive] 50027 [Tool To Make For Adjusting The Bevel Drive]

Reference

PAGE

Planetary drive and hub - Disassemble

25.3 / 6

Planetary drive and hub - Assemble

25.3 / 7

Planetary drive and hub - Assemble

25.3 / 7

Planetary drive and hub - Assemble

25.3 / 7

Planetary drive and hub - Assemble

25.3 / 8

Planetary drive and hub - Disassemble

25.3 / 9

Planetary drive and hub - Disassemble

25.3 / 9

Steering knuckle and king pin - Adjust

25.3 / 12

Steering knuckle and king pin - Adjust

25.3 / 12

Wheel hub - Replace

25.3 / 14

Wheel hub - Replace

25.3 / 14

Wheel hub - Replace

25.3 / 14

Powered rear axle - Special tools

27.1 / 5

Powered rear axle - Special tools

27.1 / 5

Powered rear axle - Special tools

27.1 / 5

Powered rear axle - Special tools

27.1 / 5

Powered rear axle - Special tools

27.1 / 5

Powered rear axle - Special tools

27.1 / 5

Powered rear axle - Special tools Powered rear axle - Special tools Powered rear axle - Special tools

27.1 / 5 27.1 / 5 27.1 / 5

Powered rear axle - Special tools

27.1 / 5

Powered rear axle - Special tools

27.1 / 5

Powered rear axle - Special tools

27.1 / 5

Bevel gear - Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. Bevel gear - Adjust Adjustment of the bevel drive, checking clearance between the pinion / ring gear teeth and bearing pre-load. Differential lock hydraulic control - Adjust

27.2 / 5

50041 [Differential Block Sleeve Adjuster] 50041 [Differential Block Differential lock hydraulic control - Adjust Sleeve Adjuster] 380000227 [Axle Housing And Rear electro-hydraulic control - Special tools Differential Unit Lifting Hook]

84568014 22/03/2013

27.2 / 5

27.2 / 9 27.2 / 9 31.1 / 4

Genuine 380000243 [Transmission Clutch Spring Compressor] 380000258 [Handgrip ] 50135 [Drift ] 380000227 [Axle Housing And Differential Unit Lifting Hook] 380000227 [Axle Housing And Differential Unit Lifting Hook] 380000243 [Transmission Clutch Spring Compressor] 380000243 [Transmission Clutch Spring Compressor] 380000243 [Transmission Clutch Spring Compressor] 380000243 [Transmission Clutch Spring Compressor] 380000223 [Water Pump Puller used on 4.5L & 6.7L NEF Engines] 380000240 [Hydraulic Pressure Test Kit] 293190 [Trailer Brake Fitting] 380000240 [Hydraulic Pressure Test Kit] 293190 [Trailer Brake Fitting] 380000240 [Hydraulic Pressure Test Kit] 380000224 [Hydraulic Lift Lifting Hook] 380000467 [Hydraulic Lift Piston Installation Ring] 291359-2 [Hydraulic Lift Lifting Hook] 380000238 [Hydraulic Lift Housing Lifting Frame Adapter] 380000224 [Hydraulic Lift Lifting Hook] 380000238 [Hydraulic Lift Housing Lifting Frame Adapter] 380000238 [Hydraulic Lift Housing Lifting Frame Adapter] 380000224 [Hydraulic Lift Lifting Hook] 380000553 [Pressure Gauge 0-250 Bar] 380000621 [Quick Release Coupler (Female) x 1/4 NPTF] 380000545 [Pressure Gauge Hose] 380000570 [Tee Adapter, 1/4 ORFS (Female) x 1/4 ORFS (Male) x 7/16 UNF (Female)] 380000599 [Blanking Cap, 11/16 ORFS] 380000492 [7/16 UNF Male Quick Release Adapter]

Reference

PAGE

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 31.3 / 14

Power Take-Off

31.3 / 17

Power Take-Off

31.3 / 21

Power Take-Off

31.3 / 21

Power Take-Off

31.3 / 23

Power Take-Off

31.3 / 23

Brake pump - Remove

33.1 / 16

Trailer brake valve - Special tools

33.4 / 3

Trailer brake hydraulic control - Leakage test Trailer brake hydraulic control - Leakage test

33.4 / 20 33.4 / 20

Trailer brake hydraulic control - Leakage test Remote control valve Closed center mechanical remote valve Special tools Rear three-point hitch - Special tools

33.4 / 20 35.3 / 4

Rear three-point hitch - Special tools

37.1 / 4

Rear three-point hitch - Special tools

37.1 / 5

Rear hitch housing - Remove

37.1 / 10

Rear hitch housing - Remove

37.1 / 10

Rear hitch housing - Remove

37.1 / 10

Rear hitch housing - Install

37.1 / 11

Rear hitch housing - Install

37.1 / 11

Hydraulic control components - Special tools

41.1 / 3

Hydraulic control components - Special tools

41.1 / 3

Hydraulic control components - Special tools

41.1 / 3

Hydraulic control components - Special tools

41.1 / 3

Hydraulic control components - Special tools

41.1 / 3

Hydraulic control components - Special tools

41.1 / 3

84568014 22/03/2013

37.1 / 4

Genuine 380000223 [Water Pump Puller used on 4.5L & 6.7L NEF Engines] 380000240 [Hydraulic Pressure Test Kit] 380000281 [Rotoglyd Steering Seal Installer] 380000281 [Rotoglyd Steering Seal Installer] 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] 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]

Reference

PAGE

Hydraulic control components - Special tools

41.1 / 3

Hydraulic control components - Special tools

41.1 / 3

Hydraulic control components - Special tools

41.1 / 3

Power steering control valve - Install power steering spool valve

41.1 / 14

Power steering control valve - Remove

41.1 / 17

Power steering control valve - Pressure test for the power steering relief valve

41.1 / 20

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

41.1 / 20

valve - Pressure test for the power

41.1 / 20

valve - Pressure test for the power

41.1 / 20

valve - Pressure test for the power

41.1 / 20

valve - Pressure test for the power

41.1 / 20

valve - Pressure test for the power

41.1 / 20

valve - Pressure test for the power

41.1 / 20

Power steering control valve - Pressure test for the power steering relief valve Power steering control valve - Pressure test for the power steering relief valve Power steering control valve - Pressure test for the power steering relief valve Power steering control valve - Pressure test for the power steering relief valve Power steering control valve - Pressure test for the power steering relief valve Power steering pump - Pressure test power steering/low pressure circuit pump

41.1 / 20

Power steering pump - Pressure test power steering/low pressure circuit pump Power steering pump - Pressure test power steering/low pressure circuit pump Power steering pump - Pressure test power steering/low pressure circuit pump Power steering pump - Pressure test power steering/low pressure circuit pump Power steering pump - Pressure test power steering/low pressure circuit pump Power steering pump - Pressure test power steering/low pressure circuit pump Power steering pump - Pressure test power steering/low pressure circuit pump

41.2 / 4

Power steering pump - Pressure test power steering/low pressure circuit pump

41.2 / 5

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41.2 / 4 41.2 / 4 41.2 / 4 41.2 / 4 41.2 / 4 41.2 / 5

Genuine 380000553 [Pressure Gauge 0-250 Bar] 380000621 [Quick Release Coupler (Female) x 1/4 NPTF] 380000545 [Pressure Gauge Hose] 380001268 [Engine Belt Tension Meter ] 380000843 [Diagnostic Test Switch] 380000843 [Diagnostic Test Switch] 380000843 [Diagnostic Test Switch] 380000843 [Diagnostic Test Switch] 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)] 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)]

Reference

PAGE

41.2 / 5

Electronic module - View HH MENU ACCESS

55.6 / 8

Electronic module - H1 - Calibration procedures

55.6 / 38

Electronic module - H1 - Calibration procedures

55.6 / 38

Electronic module - H1 - Calibration procedures

55.6 / 39

Electronic module - H1 - Calibration procedures

55.6 / 40

Electronic module - H1 - Calibration procedures

55.6 / 42

Electronic module - H1 - Calibration procedures

55.6 / 44

Instrument cluster - Dynamic description setting hours worked

55.10 / 29

3010-Boost temperature sensor - signal above range maximum

55.11 / 130

3010-Boost temperature sensor - signal above range maximum

55.11 / 130

3010-Boost temperature sensor - signal above range maximum

55.11 / 131

3010-Boost temperature sensor - signal above range maximum

55.11 / 132

3011-Boost temperature sensor - signal below range minimum

55.11 / 134

3011-Boost temperature sensor - signal below range minimum

55.11 / 134

3011-Boost temperature sensor - signal below range minimum

55.11 / 135

3011-Boost temperature sensor - signal below range minimum

55.11 / 136

3016-Fuel temperature sensor - signal below range minimum

55.11 / 140

3016-Fuel temperature sensor - signal below range minimum

55.11 / 140

3016-Fuel temperature sensor - signal below range minimum

55.11 / 141

3016-Fuel temperature sensor - signal below range minimum

55.11 / 141

3019-Boost pressure sensor - signal above range maximum

55.11 / 143

3019-Boost pressure sensor - signal above range maximum

55.11 / 143

3019-Boost pressure sensor - signal above range maximum

55.11 / 144

3037-Boost pressure sensor - signal low

55.11 / 151

3088-Crankshaft sensor - no signal

55.11 / 168

3088-Crankshaft sensor - no signal

55.11 / 168

84568014 22/03/2013

41.2 / 5 41.2 / 5 55.4 / 3

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)] 380000843 [Diagnostic Test Switch] 380000315 [Recovery And Rrecharge Portable System (For Discharging And Recovering Of The Refrigerant)]

Reference

PAGE

3088-Crankshaft sensor - no signal

55.11 / 169

3088-Crankshaft sensor - no signal

55.11 / 169

3089-Crankshaft sensor - invalid signal

55.11 / 172

3089-Crankshaft sensor - invalid signal

55.11 / 172

3797-Diesel particulate filter pressure sensor: SRC high for PFlt differential pressure sensor 2450-Configuration error

55.11 / 482

Cab and platform - Remove

84568014 22/03/2013

55.11 / 751 90.1 / 3

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

84568014 22/03/2013 EN