New Hollan Service Manual 200 Series

SERVICE MANUAL L213 / L215 / L218 / L220 L223 / L225 / L230 200 Series Skid Steer Loader C227 / C232 / C238 200 Series Compact Track Loader

Part number 84522361 1st edition English June 2011 Printed in U.S.A. Copyright © 2011 CNH America LLC. All Rights Reserved. New Holland is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.

SERVICE MANUAL

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011 EN

Contents INTRODUCTION HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS A PRIMARY HYDRAULIC POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.A SECONDARY HYDRAULIC POWER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.12.A HYDRAULIC COMMAND SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.14.A HIGH-FLOW HYDRAULIC POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.16.A ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A LIGHTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.40.A ELECTRONIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A

ENGINE AND PTO IN ................................................................... B ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A

TRANSMISSION, DRIVE AND PTO OUT ........................................ C TRANSMISSION Hydrostatic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.F

AXLES, BRAKES AND STEERING................................................. D Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.15.A Final drive Hydraulic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.15.C STEERING Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.20.B PARKING BRAKE Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.32.C WHEELS AND TRACKS Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.50.B WHEELS AND TRACKS Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.50.C

FRAME AND CAB ........................................................................ E FRAME Primary frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.10.B SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.20.A 84522361 15/06/2011

USER CONTROLS AND SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.A USER CONTROLS AND SEAT Operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.C USER PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.34.A ENVIRONMENT CONTROL Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.40.C SAFETY SECURITY ACCESSORIES Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.50.B

FRAME POSITIONING ................................................................. F STABILISING Ballasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F.20.B

TOOL POSITIONING .................................................................... G LIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.10.A TILTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.20.A LEVELLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.30.A SECONDARY FUNCTIONS Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.90.C

HITCH AND WORKING TOOL ....................................................... H BOOM Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.20.B ARM TOOL ATTACHMENT Tilt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.30.C SINGLE ARM Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.40.B SINGLE ARM TOOL ATTACHMENT Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.50.C

EXCAVATING AND LANDSCAPING ............................................... J DIGGING Non-articulated digging tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.20.B CARRYING Unarticulated tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.50.B COUPLING Mechanical coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.80.B COUPLING Hydraulic coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.80.C

84522361 15/06/2011

84522361 15/06/2011

INTRODUCTION

84522361 15/06/2011

1

Contents INTRODUCTION Foreword - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 - Series

Safety rules - Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2 - Series

General specification - General Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

84522361 15/06/2011

2

INTRODUCTION

Foreword - Ecology and the environment Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances which are required by advanced technology, sound judgement should govern the use and disposal of products of a chemical and petrochemical nature. NOTICE: The following are recommendations which may be of assistance: •

Become acquainted with and ensure that you understand the relative legislation applicable to your country.

•

Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safely store, use and dispose of these substances.

•

Agricultural consultants will, in many cases, be able to help you as well.

HELPFUL HINTS •

Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems which may cause considerable spillage.

•

In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances which may be harmful to your health.

•

Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.

•

Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources.

•

Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil but should be collected and disposed of properly.

•

Do not open the air-conditioning system yourself. It contains gases which should not be released into the atmosphere. Your NEW HOLLAND CONSTRUCTION dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the system properly.

•

Repair any leaks or defects in the engine cooling or hydraulic system immediately.

•

Do not increase the pressure in a pressurized circuit as this may lead to a component failure.

•

Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of oils, coolant, etc.

84522361 15/06/2011

3

INTRODUCTION

Safety rules 2 - Series

Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you. Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. The color associated with WARNING is ORANGE. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color associated with Notice is BLUE. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information which clarifies steps, procedures, or other information in this manual. Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

84522361 15/06/2011

4

INTRODUCTION

Safety rules - Personal Safety Carefully study these precautions, and those included in the external attachment operators manual, and insist that they be followed by those working with and for you. 1.

Thoroughly read and understand this manual and the attachment operators manual before operating this or any other equipment.

2.

Be sure everyone is clear of the machine before starting. Blow the horn, if equipped, three times before starting engine.

3.

Only the operator should be on the machine when in operation. Never allow anyone to climb on to the machine while it is in motion. If the machine is equipped with an Instructors Seat, this must only be used for training purposes. Passengers must not be allowed to use the Instructors Seat.

4.

Keep all shields in place. Never work around the machine or any of the attachments while wearing loose clothing that might catch on moving parts.

5.

Observe the following precautions whenever lubricating the machine or making adjustments. •

Disengage all clutching levers or switches.

•

Lower the attachment, if equipped, to the ground or raise the attachment completely and engage the cylinder safety locks . Completing these actions will prevent the attachment from lowering unexpectedly.

•

Engage the parking brake.

•

Shut off the engine and remove the key.

6.

Always keep the machine in gear while going downhill.

7.

The machine should always be equipped with sufficient front or rear axle weight for safe operation.

8.

Under some field conditions, more weight may be required at the front or rear axle for adequate stability. This is especially important when operating in hilly conditions or/when using heavy attachments.

9.

Always lower the attachment, shut off the engine, set the parking brake, engage the transmission gears and remove the key before leaving the operators platform.

10.

If the attachment or machine should become obstructed or plugged; set the parking brake, shut off the engine and remove the key, engage the transmission gears, wait for all machine or attachment motion to come to a stop, before leaving the operators platform to removing the obstruction or plug.

11.

Never disconnect or make any adjustments to the hydraulic system unless the machine and/or the attachment is lowered to the ground or the safety lock(s) is in the engaged position.

12.

Use of the flashing lights is highly recommended when operating on a public road.

13.

When transporting on a road or highway, use accessory lights and devices for adequate warning to the operators of other vehicles. In this regard, check local government regulations. Various safety lights and devices are available from your NEW HOLLAND CONSTRUCTION dealer.

14.

Practice safety 365 days a year.

15.

Keep all your equipment in safe operating condition.

16.

Keep all guards and safety devices in place.

17.

Always set the parking brake, shut off the engine and remove the key, engage the transmission gears, wait for all machine or attachment motion to come to a stop, before leaving the operators platform to service the machine and attachment.

18.

Remember: A careful operator is the best insurance against an accident.

19.

Extreme care should be taken in keeping hands and clothing away from moving parts.

84522361 15/06/2011

5

INTRODUCTION

Safety rules

BT09A213

1

84522361 15/06/2011

6

INTRODUCTION

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

84522361 15/06/2011

7

INTRODUCTION

Torque - Minimum tightening torques for normal assembly 2 - Series

METRIC NON-FLANGED HARDWARE NOM. SIZE CLASS 8.8 BOLT and CLASS 8 NUT PLATED UNPLATED W/ZnCr M4 M5 M6 M8

2.2 N·m (19 lb in) 4.5 N·m (40 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)

M10

37 N·m (27 lb ft)

M12

64 N·m (47 lb ft)

M16 M20 M24

158 N·m (116 lb ft) 319 N·m (235 lb ft) 551 N·m (410 lb ft)

2.9 N·m (26 lb in) 5.9 N·m (52 lb in) 10 N·m (89 lb in) 25 N·m (217 lb in) 49 N·m (36 lb ft) 85 N·m (63 lb ft) 210 N·m (155 lb ft) 425 N·m (313 lb ft) 735 N·m (500 lb ft)

CLASS 10.9 BOLT and CLASS 10 NUT PLATED UNPLATED W/ZnCr 3.2 N·m (28 lb 4.2 N·m (37 lb in) in) 6.4 N·m (57 lb 8.5 N·m (75 lb in) in) 11 N·m (96 lb 15 N·m (128 lb in) in) 26 N·m (234 lb 35 N·m (311 lb in) in) 70 N·m (51 lb 52 N·m (38 lb ft) ft) 121 N·m (90 lb 91 N·m (67 lb ft) ft) 225 N·m (166 lb 301 N·m (222 ft) lb ft) 440 N·m (325 lb 587 N·m (433 ft) lb ft) 762 N·m (560 lb 1016 N·m (750 ft) lb ft)

LOCKNUT CL.8 W/CL8.8 BOLT

2 N·m (18 lb in) 4 N·m (36 lb in) 6.8 N·m (60 lb in) 17 N·m (151 lb in) 33 N·m (25 lb ft) 58 N·m (43 lb ft) 143 N·m (106 lb ft) 290 N·m (214 lb ft) 501 N·m (370 lb ft)

LOCKNUT CL.10 W/CL10.9 BOLT 2.9 N·m (26 lb in) 5.8 N·m (51 lb in) 10 N·m (89 lb in) 24 N·m (212 lb in) 48 N·m (35 lb ft) 83 N·m (61 lb ft) 205 N·m (151 lb ft) 400 N·m (295 lb ft) 693 N·m (510 lb ft)

NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque specifications are shown in pound-feet.

84522361 15/06/2011

8

INTRODUCTION

METRIC FLANGED HARDWARE NOM. SIZE

CLASS 8.8 BOLT and CLASS 8 NUT

UNPLATED M4 M5 M6 M8

2.4 N·m (21 lb in) 4.9 N·m (43 lb in) 8.3 N·m (73 lb in) 20 N·m (179 lb in)

M10

40 N·m (30 lb ft)

M12

70 N·m (52 lb ft)

M16 M20 M24

174 N·m (128 lb ft) 350 N·m (259 lb ft) 607 N·m (447 lb ft)

PLATED W/ZnCr 3.2 N·m (28 lb in) 6.5 N·m (58 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in) 54 N·m (40 lb ft) 93 N·m (69 lb ft) 231 N·m (171 lb ft) 467 N·m (345 lb ft) 809 N·m (597 lb ft)

CLASS 10.9 BOLT and CLASS 10 NUT

UNPLATED

IDENTIFICATION Metric Hex head and carriage bolts, classes 5.6 and up

1.

Manufacturer's Identification

2.

Property Class

1

Metric Hex nuts and locknuts, classes 05 and up

20083681

2

84522361 15/06/2011

9

LOCKNUT CL.10 W/CL10.9 BOLT

2.2 N·m (19 lb in) 4.4 N·m (39 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)

3.1 N·m (27 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in)

PLATED W/ZnCr

3.5 N·m (31 lb 4.6 N·m (41 lb in) in) 7.0 N·m (62 lb 9.4 N·m (83 lb in) in) 12 N·m (105 lb 16 N·m (141 lb in) in) 29 N·m (257 lb 39 N·m (343 lb in) in) 77 N·m (56 lb 57 N·m (42 lb ft) ft) 100 N·m (74 lb 134 N·m (98 lb ft) ft) 248 N·m (183 lb 331 N·m (244 ft) lb ft) 484 N·m (357 lb 645 N·m (476 ft) lb ft) 838 N·m (618 lb 1118 N·m (824 ft) lb ft)

20083680

LOCKNUT CL.8 W/CL8.8 BOLT

37 N·m (27 lb ft) 53 N·m (39 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft) 158 N·m (116 lb ft) 318 N·m (235 lb ft) 552 N·m (407 lb ft)

226 N·m (167 lb ft) 440 N·m (325 lb ft)

INTRODUCTION

1.

Manufacturer's Identification

2.

Property Class

3.

Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60 ° apart indicate Class 10 properties, and marks 120 ° apart indicate Class 8.

INCH NON-FLANGED HARDWARE NOMINAL SIZE

SAE GRADE 5 BOLT and NUT UNPLATED or PLATED SILVER

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

8 N·m (71 lb in) 17 N·m (150 lb in) 30 N·m (22 lb ft) 48 N·m (36 lb ft) 74 N·m (54 lb ft) 107 N·m (79 lb ft) 147 N·m (108 lb ft) 261 N·m (193 lb ft) 420 N·m (310 lb ft) 630 N·m (465 lb ft)

SAE GRADE 8 BOLT and NUT

UNPLATED PLATED W/ZnCr or PLATED GOLD SILVER 11 N·m (97 lb in) 23 N·m (204 lb in) 40 N·m (30 lb ft) 65 N·m (48 lb ft) 98 N·m (73 lb ft) 142 N·m (105 lb ft) 196 N·m (145 lb ft) 348 N·m (257 lb ft) 561 N·m (413 lb ft) 841 N·m (620 lb ft)

12 N·m (106 lb in) 24 N·m (212 lb in) 43 N·m (31 lb ft) 68 N·m (50 lb ft) 104 N·m (77 lb ft) 150 N·m (111 lb ft) 208 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft)

LOCKNUT GrB W/ Gr5 BOLT

LOCKNUT GrC W/ Gr8 BOLT

PLATED W/ZnCr GOLD 16 N·m (142 lb in) 32 N·m (283 lb in) 57 N·m (42 lb ft) 91 N·m (67 lb ft) 139 N·m (103 lb ft) 201 N·m (148 lb ft) 277 N·m (204 lb ft) 491 N·m (362 lb ft) 791 N·m (584 lb ft) 1187 N·m (875 lb ft)

12.2 N·m (109 lb in) 17.5 N·m (155 lb 25 N·m (220 lb in) in)

8.5 N·m (75 lb in)

31 N·m (23 lb ft) 44 N·m (33 lb ft) 50 N·m (37 lb ft) 71 N·m (53 lb ft) 76 N·m (56 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb ft) 153 N·m (113 lb 215 N·m (159 lb ft) ft) 271 N·m (200 lb 383 N·m (282 lb ft) ft) 437 N·m (323 lb 617 N·m (455 lb ft) ft) 654 N·m (483 lb 924 N·m (681 lb ft) ft)

111 N·m (82 lb ft)

NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in through 1 in hardware torque specifications are shown in pound-feet.

84522361 15/06/2011

10

INTRODUCTION

INCH FLANGED HARDWARE NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL NUT NUT SIZE PLATED UNPLATED PLATED UNPLATED W/ZnCr or PLATED W/ZnCr or PLATED GOLD SILVER GOLD SILVER 1/4

9 N·m (80 lb in)

5/16

19 N·m (168 lb in)

3/8

33 N·m (25 lb ft)

7/16

53 N·m (39 lb ft)

1/2

81 N·m (60 lb ft)

9/16 5/8 3/4 7/8 1

117 N·m (86 lb ft) 162 N·m (119 lb ft) 287 N·m (212 lb ft) 462 N·m (341 lb ft) 693 N·m (512 lb ft)

12 N·m (106 lb in) 25 N·m (221 lb in) 44 N·m (33 lb ft) 71 N·m (52 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb ft) 216 N·m (159 lb ft) 383 N·m (282 lb ft) 617 N·m (455 lb ft) 925 N·m (682 lb ft)

13 N·m (115 lb in) 26 N·m (230 lb in) 47 N·m (35 lb ft) 75 N·m (55 lb ft) 115 N·m (85 lb ft) 165 N·m (122 lb ft) 228 N·m (168 lb ft) 405 N·m (299 lb ft) 653 N·m (482 lb ft) 979 N·m (722 lb ft)

17 N·m (150 lb in) 35 N·m (310 lb in) 63 N·m (46 lb ft) 100 N·m (74 lb ft) 153 N·m (113 lb ft) 221 N·m (163 lb ft) 304 N·m (225 lb ft) 541 N·m (399 lb ft) 871 N·m (642 lb ft) 1305 N·m (963 lb ft)

LOCKNUT GrF W/ Gr5 BOLT

8 N·m (71 lb in) 17 N·m (150 lb in)

LOCKNUT GrG W/ Gr8 BOLT

12 N·m (106 lb in) 24 N·m (212 lb in)

30 N·m (22 lb ft) 43 N·m (32 lb ft) 48 N·m (35 lb ft) 68 N·m (50 lb ft) 74 N·m (55 lb ft) 106 N·m (78 lb ft) 147 N·m (108 lb ft) 261 N·m (193 lb ft) 421 N·m (311 lb ft) 631 N·m (465 lb ft)

104 N·m (77 lb ft) 157 N·m (116 lb ft) 207 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft)

IDENTIFICATION Inch Bolts and free-spinning nuts

20083682

3

Grade Marking Examples 1 2 3

Grade 2 - No Marks Grade 5 - Three Marks Grade 8 - Five Marks

SAE Grade Identification 4 Grade 2 Nut - No Marks 5 Grade 5 Nut - Marks 120 ° Apart 6 Grade 8 Nut - Marks 60 ° Apart

84522361 15/06/2011

11

INTRODUCTION

Inch Lock Nuts, All Metal (Three optional methods)

20090268

4

Grade Identification Grade Grade A Grade B Grade C

Corner Marking Method (1) No Notches One Circumferential Notch Two Circumferential Notches

Flats Marking Method (2) No Mark Letter B Letter C

84522361 15/06/2011

12

Clock Marking Method (3) No Marks Three Marks Six Marks

INTRODUCTION

General specification - General Welding WARNING Explosion hazard! Batteries emit explosive gases. Always ventilate when using in an enclosed area or when charging. Keep the battery away from sparks, open flames, and other ignition sources. Failure to comply could result in death or serious injury. W0369A

Use a 7013 or 7011 welding rod or wire that meets the following American Welding Society (AWS) specifications: ER80S-D2, ER70S-6 or E70C-M6-H4. NOTICE: ALWAYS disconnect the battery (both terminals) before welding on any part of the machine. Failure to do so may cause damage to sensitive electrical components. NOTICE: Locate the welding ground as close as possible to the area to be welded. Do not allow the ground current to pass through any roller type bearing. Arcing inside the roller bearing can result in severe machine damage.

84522361 15/06/2011

13

INTRODUCTION

84522361 15/06/2011

14

SERVICE MANUAL HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

A

Contents HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A

PRIMARY HYDRAULIC POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

SECONDARY HYDRAULIC POWER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.12.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

HYDRAULIC COMMAND SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.14.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

HIGH-FLOW HYDRAULIC POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.16.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

LIGHTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.40.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

ELECTRONIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

A

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A PRIMARY HYDRAULIC POWER SYSTEM - 10.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

A.10.A / 1

Contents HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A PRIMARY HYDRAULIC POWER SYSTEM - 10.A

TECHNICAL DATA PRIMARY HYDRAULIC POWER SYSTEM General specification for the 24.9cc Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L218, L220

General specification of the 24.9cc Gear pump with high flow 12.5cc pump . . . . . . . . . . . . . . . . . . . . . . . . 7 L218, L220

General specification of the 34.1cc gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 L223, L225, L230, C227, C232, C238

General specification of the 20.4cc gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 L213, L215

General specification for 34.1cc Front pump with rear pump 23.0cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 L230

General specification for the 34.1cc Gear pump with high flow 12.5cc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C227

General specification for the 34.1cc Gear pump with high flow 18.3cc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 L223, L225, L230, C232, C238

Filter General specification Hydraulic oil return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 General specification Hydraulic oil supply strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Control valve General specification of the Ride Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 General specification of the EH Control Loader Valve for all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 General specification Mechanical Hand Control Loader valve on all models . . . . . . . . . . . . . . . . . . . . . . . 17 L213, L215, L218, L220

General specification of Mechanical Foot Control Loader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

General specification of the EH and Mechanical boom override valve on all models . . . . . . . . . . . . . . . . 19 General specification of Secondary Auxiliary Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 General specification High Flow Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

FUNCTIONAL DATA PRIMARY HYDRAULIC POWER SYSTEM Overview of Contaminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Overview EH Drive Pattern Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls 84522361 15/06/2011

A.10.A / 2

Component identification of hydraulic valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L223, L225, L230, C232, C238

Component identification of hydraulic valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 L218, L220, C227

Component identification of hydraulic valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 L213, L215

Component identification of pumps of large frame models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 L223, L225, L230, C232, C238

Component identification of pumps on medium frame models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 L218, L220, C227

Component identification of pumps on small frame models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 L213, L215

Component identification of cylinders on small frame models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 L213, L215

Component identification of cylinders on medium frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 L218, L220, C227

- Component identification of cylinders on large frame models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 L223, L225, L230, C232, C238

Component identification of hydraulic motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 L223, L225, L230, C232, C238

Component identification of hydraulic motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 L218, L220

Component identification of hydraulic motors on small frame models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 L213, L215

Hydraulic schematic frame 01 Two speed drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Single speed drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Hydraulic schematic frame 03 Valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

Hydraulic schematic frame 04 Enhanced high flow option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Hydraulic schematic frame 01 Two speed drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

Hydraulic schematic frame 02 Single speed drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

Hydraulic schematic frame 03 Valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

Hydraulic schematic frame 01 Two speed track drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Hydraulic schematic frame 02 Valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Hydraulic schematic frame 03 Enhanced high flow option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Hydraulic schematic frame 01 Two speed drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 L223, L225, L230

Hydraulic schematic frame 02 Valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.10.A / 3

Hydraulic schematic frame 03 Enhanced high flow option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Hydraulic schematic frame 01 Two speed drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 L218 Electro hydraulic controls, L220 Electro hydraulic controls

Hydraulic schematic frame 02 Single speed drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

Hydraulic schematic frame 03 Valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls

Hydraulic schematic frame 01 Single speed drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls

Hydraulic schematic frame 02 Valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls

Hydraulic schematic frame 01 Single speed drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 L213 Electro hydraulic controls, L215 Electro hydraulic controls

Hydraulic schematic frame 02 Valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 L213 Electro hydraulic controls, L215 Electro hydraulic controls

Control valve Overview Loader Lift Control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Overview Loader bucket control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Overview Loader arm float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

SERVICE PRIMARY HYDRAULIC POWER SYSTEM Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Relief valve Flow test Loader main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Pressure test Loader valve main relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Hydraulic pump Flow test Loader hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Charge pump Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Pressure test (Machines Equipped with EH Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Reservoir Apply vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Filter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Oil cooler Remove for models equipped with ISM engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 L213, L215, L218, L220

Install for machines equipped with ISM engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 L213, L215, L218, L220

84522361 15/06/2011

A.10.A / 4

Remove - for machines equipped with F5C engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 L223, L225, L230, C227, C232, C238

Install - for machines equipped with F5C engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 L223, L225, L230, C227, C232, C238

84522361 15/06/2011

A.10.A / 5

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - General specification for the 24.9cc Gear Pump L218, L220

Auxiliary pump Manufacturer

Shimadzu

Type

Gear pump

Direction of Rotation

Clockwise - viewed looking into input shaft.

Test Speed

1800 RPM

Test Pressure

172.0 bar (2494.6 psi)

Test Flow

42.5 l/min (11.2 US gpm)

Displacement

24.9 cm³ (1.5 in³)

Input shaft

13 tooth spline

Speed

400 - 3500 RPM

Drive

Direct

84522361 15/06/2011

A.10.A / 6

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - General specification of the 24.9cc Gear pump with high flow 12.5cc pump L218, L220

Auxiliary pump with high flow pump Manufacturer

Shimadzu

Type

Gear pump

Direction of Rotation

Clockwise - viewed looking into input shaft.

Displacement - load/aux section

24.9 cm³ (1.5 in³)

High flow section displacement

12.5 cm³ (0.8 in³)

Test Speed

1800 RPM

Test Pressure

172.0 bar (2494.6 psi)

Test Flow 1

42.5 l/min (11.2 US gpm)

Test Flow 2

20.4 l/min (5.4 US gpm)

Input shaft

13 tooth spline

Speed

500 - 3500 RPM

Drive

Direct

Relief valve setting

210 bar (3045 psi)

84522361 15/06/2011

A.10.A / 7

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - General specification of the 34.1cc gear pump L223, L225, L230, C227, C232, C238

Auxiliary pump Manufacturer

Shimadzu

Type

Gear pump

Direction of Rotation

Clockwise - viewed looking into input shaft.

Displacement, loader/aux section

34.1 cm³ (2.1 in³)

Speed

400 - 3000 RPM

Test Speed

1800 RPM

Test Pressure

172.0 bar (2494.6 psi)

Test Flow

57 l/min (15.1 US gpm)

Drive

Direct

Input shaft

13 tooth spline

Relief valve setting

210 bar (3045 psi)

84522361 15/06/2011

A.10.A / 8

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - General specification of the 20.4cc gear pump L213, L215

Loader pump Manufacturer

Shimadzu

Type

Gear pump

Direction of Rotation

Clockwise - viewed looking into input shaft.

Test Speed

1800 RPM

Test Pressure

172.0 bar (2494.6 psi)

Test Flow

40.1 l/min (10.6 US gpm)

Displacement

20.4 cm² (3.2 in²)

Input shaft

13 tooth spline

Speed

900 - 3500 RPM

Drive

Direct

84522361 15/06/2011

A.10.A / 9

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - General specification for 34.1cc Front pump with rear pump 23.0cc L230

Manufacturer

Shimadzu

Type

Gear pump

Direction of Rotation

Clockwise - viewed looking into input shaft.

Displacement

34.1 cm³ (2.1 in³)

Front pump rated pressure

210 bar (3045.0 psi)

Input shaft

13 tooth spline

Speed

400 - 3000 RPM

Rear pump rated pressure

28 bar (406 psi)

Drive

Direct

Normal pressure

193 bar (2799 psi)

Surge pressure

262 bar (3799 psi)

Relief valve setting

210 bar (3045 psi)

84522361 15/06/2011

A.10.A / 10

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - General specification for the 34.1cc Gear pump with high flow 12.5cc. C227

Manufacturer

Shimadzu

Type

Gear pump

Direction of Rotation

Clockwise - viewed looking into input shaft.

Displacement, loader/aux section

34.1 cm³ (2.1 in³)

Test Speed

1800 RPM

Test Pressure

172.0 bar (2494.6 psi)

Test Flow (loader / aux)

57.0 l/min (15.1 US gpm)

Test Flow (high flow sect.)

20.4 l/min (5.4 US gpm)

High flow section displacement

12.5 cm³ (0.8 in³)

Input shaft

13 tooth spline

Speed

500 - 3000 RPM

Drive

Direct

84522361 15/06/2011

A.10.A / 11

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - General specification for the 34.1cc Gear pump with high flow 18.3cc. L223, L225, L230, C232, C238

Manufacturer

Shimadzu

Type

Gear pump

Direction of Rotation

Clockwise - viewed looking into input shaft.

Displacement

34.1 cm³ (2.1 in³)

High flow pump displacement

18.3 cm³ (1.1 in³)

Test Speed

1800 RPM

Test Pressure

172.0 bar (2494.6 psi)

Test Flow 1

57.0 l/min (15.1 US gpm)

Test Flow 2

31.1 l/min (8.2 US gpm)

Input shaft

13 tooth spline

Speed

500 - 2700 RPM

Drive

Direct

84522361 15/06/2011

A.10.A / 12

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Filter - General specification Hydraulic oil return filter Filter type

Spin-on

Filter media

Synthetic

Filter efficiency

98.7 % at 6 micron

Flow rating

132 l/min (35 US gpm)

System operating pressure

14 bar (200 psi) +/- 3 bar (50 psi)

Minimum static burst pressure

69 bar (1000 psi)

Operating temperature range

-30 - 107 °C (-22 - 225 °F)

84522361 15/06/2011

A.10.A / 13

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Filter - General specification Hydraulic oil supply strainer Filter type

60 mesh wire strainer

Filter efficiency

approximately 250 micron

Flow rating

113 l/min (30 US gpm)

Operating temperature range

up to 110 °C (230 °F)

Internal thread

-24 SAE straight thread o-ring boss 1 7/8-12 thread

External thread

-48 SAE straight thread o-ring boss 3 3/8-12 thread

84522361 15/06/2011

A.10.A / 14

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control valve - General specification of the Ride Control Valve Valve Configuration:

Solenoid operated, 4 way, 2 position, direct acting, spool type hydraulic cartridge valve.

Hydraulic Requirements:

Flow = 22.7 l/min (6 US gpm). System Pressure = 210 bar (3045 psi).

Electrical Requirements:

Operating Voltage = 14 V Maximum Power = 22 W Polarity = Power: Pin 1 or A, Ground: Pin 2 or B Solenoid connection type = Duetsch DT series.

Operating Temperature Range:

-30 - 107 °C (-22 - 225 °F)

Port Identification Chart:

(1) (2) (3) (4)

Tank Return Lift Cylinder Rod Port Accumulator Lift Cylinder Base Port

84522361 15/06/2011

A.10.A / 15

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control valve - General specification of the EH Control Loader Valve for all models Main Relief Setting: Circuit Relief Setting:

Spool Position Sensor Output:

Electrical Requirements:

Electrical Connector Types:

Operating Temperature Range: Port Identification Chart:

3000 psi (+145/-0) at 23 US gpm (A1) 3263 psi (+145/-73) (A2) 3481 psi (+145/-73) (B2) 3336 psi (+145/-73) Initial valve flow in negative direction must occur when sensor output is 1.9 - 2.3 V Initial valve flow in positive direction must occur when sensor output is 2.7 - 3.1 V Operating Voltage = 14 V Maximum Power = 22 W Polarity = Power: Pin 1 or A, Ground: Pin 2 or B Work port lockout solenoid: Deutsche DT series. EH Auxiliary PRV: Deutsche DT series. Spool position sensor: Deutsche DT series -30 - 107 °C (-22 - 225 °F) (P) Supply Inlet (T) Tank Return (A1) Lift Cylinder Base End (B1) Lift Cylinder Rod End (A2) Tilt Cylinder Rod End (B2) Tilt Cylinder Base End (A3) Auxiliary Male Coupler (B3) Auxiliary Female Coupler (PLV) Work port Lockout Pilot Supply (PLV) (Drain) Work port Lockout Tank Return (P2) High Flow Inlet (V) EH PRV Supply (L) EH PRV Tank Return

84522361 15/06/2011

A.10.A / 16

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control valve - General specification Mechanical Hand Control Loader valve on all models L213, L215, L218, L220

Main Relief Setting:

3000 psi (+145/-0) at 23 US gpm

Circuit Relief Setting:

(A1) 3263 psi (+145/-73) (B2) 3336 psi (+145/-73) (A2) 3481 psi (+145/-73)

Maximum Spool Force with Blocked Ports at Full Flow:

Loader Spool: 28 lb Loader Spool Detent Position: 65 lb IN; 58 lb OUT Bucket Spool: 29 lb Minimum reserve force on all spools to be greater than 5 lb

Electrical Requirements:

Operating Voltage = 14 V Maximum Power = 22 W Polarity = Power: Pin 1 or A, Ground: Pin 2 or B

Electrical Connector Types:

Work port lockout solenoid: Deutsche DT series EH Auxiliary PRV: Deutsche DT series. Spool position sensor: Deutsche DT series

Operating Temperature Range:

-30 - 107 °C (-22 - 225 °F)

Port Identification Chart:

(P) Supply Inlet (T) Tank Return (A1) Lift Cylinder Base End (B1) Lift Cylinder Rod End (A2) Tilt Cylinder Rod End (B2) Tilt Cylinder Base End (A3) Auxiliary Male Coupler (B3) Auxiliary Female Coupler (PLV) Work port Lockout Pilot Supply (PLV) (Drain) Work port Lockout Tank Return (P2) High Flow Inlet (V) EH PRV Supply (L) EH PRV Tank Return

84522361 15/06/2011

A.10.A / 17

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control valve - General specification of Mechanical Foot Control Loader Valve L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Main Relief Setting: Circuit Relief Setting:

3000 psi (+145/-0) at 23 US gpm (A1) 3263 psi (+145/-73) (B2) 3336 psi (+145/-73) (A2) 3481 psi (+145/-73) Valve Pressure Rating: 3625 psi per NFPA/T3.5.26 R2-2000 Maximum Spool Force with Blocked Loader Spool: 22.91 kgf (50.5 lbf) Ports at Full Flow: Loader Spool Detent Position: 49.90 kgf (110 lbf) in: 25.40 kgf (56 lbf) out Bucket Spool: 23.59 kgf (52 lbf) Minimum reserve force on all spools to be greater than 2 kgf (5 lbf) Electrical Requirements: Operating Voltage = 14 V Maximum Power = 22 W Polarity = Power: Pin 1 or A, Ground: Pin 2 or B Work port lockout solenoid: Deutsche DT series Electrical Connector Types: EH Auxiliary PRV: Deutsche DT series Spool position sensor: Deutsche DT series Operating Temperature Range: -30 - 107 °C (-22 - 225 °F) Port Identification Chart: (P) Supply Inlet (T) Tank Return (A1) Lift Cylinder Base End (B1) Lift Cylinder Rod End (A2) Tilt Cylinder Rod End (B2) Tilt Cylinder Base End (A3) Auxiliary Male Coupler (B3) Auxiliary Female Coupler (PLV) Work port Lockout Pilot Supply (PLV) (Drain) Work port Lockout Tank Return (P2) High Flow Inlet (V) EH PRV Supply (L) EH PRV Tank Return

84522361 15/06/2011

A.10.A / 18

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control valve - General specification of the EH and Mechanical boom override valve on all models Valve Configuration:

2-way, 2-position, manually operated, normally closed, pull to open, directional cartridge valve.

Hydraulic Requirements:

Flow = 22.7 l/min (6 US gpm). System Pressure = 210 bar (3045 psi).

Operating Temperature Range:

-30 - 107 °C (-22 - 225 °F)

Port Identification Chart:

(1) Tank Return (2) Lift Cylinder Base Port

84522361 15/06/2011

A.10.A / 19

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control valve - General specification of Secondary Auxiliary Valve Flow Divider Configuration: Flow Block Valve Configuration: Operating Pressure: Maximum Flow: Pilot Operated Relief Valve Pressure Setting: Electrical Requirements:

Electrical Connector Types: Operating Temperature Range: Operating Fluid: Port Identification Chart:

Two Position, Three Way, Spring Bias, with Hydraulic Actuation Three Position, Four Way, Spring Bias, with On/Off Solenoid Actuation 207 - +10/-0 bar (3001.5 - +145.0/-0 psi) 87 l/min (23.0 US gpm) 221 bar (3205 psi) @ 18.9 l/min (5.0 US gpm) Operating Voltage = 9 - 16 V Maximum Current = 2 A @ 12 V Polarity = Power: Pin 1 or A, Ground: Pin 2 or B Solenoid connection: Deutsche DT series . -30 - 107 °C (-22 - 225 °F) CNH MAT3509 (P) Pressure Inlet (L) To Loader Valve (T) Tank Return (A) To Auxiliary (B) To Auxiliary

Control valve - General specification High Flow Valve Valve Configuration:

Solenoid operated, 2 way, 2 position, direct acting, poppet type hydraulic cartridge valve.

Hydraulic Requirements:

Flow : 80.6 l/min (21.3 US gpm). System Pressure: 210 bar (3045.0 psi). Relief Valve Pressure Setting: 224 bar (3248.0 psi) Operating Voltage : 14 V Maximum Power : 22 W Polarity: Power: Pin 1 or A, Ground: Pin 2 or B Solenoid connection type = Duetsch DT series. -30 - 107 °C (-22 - 225 °F) (P) Pump Supply inlet (T) Tank Return (AUX) Auxiliary Valve outlet

Electrical Requirements:

Operating Temperature Range: Port Identification Chart:

84522361 15/06/2011

A.10.A / 20

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Overview of Contaminates Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways. 1.

When you drain the oil or disconnect any line.

2.

When you disassemble a component.

3.

From normal wear of the hydraulic components.

4.

From damaged or worn seals.

5.

From a damaged component in the hydraulic system.

All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause problems in the hydraulic system. The following list includes some of these problems. 1.

Cylinder rod seals leak.

2.

Control valve spools do not return to neutral.

3.

Movement of control valve spools is difficult.

4.

Hydraulic oil becomes too hot.

5.

Pump gears, housing, and other parts wear rapidly.

6.

Relief valves or check valves held open by dirt.

7.

Quick failure of components that have been repaired.

8.

Cycle times are slow; machine does not have enough power.

If your machine has any of these problems, check the hydraulic oil for contamination. See types of contamination below. If you find contamination, use the Portable Filter to clean the hydraulic system. NOTE: There are two types of contamination, microscopic and visible. Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil. These particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by testing in a laboratory. Examples of the problems: 1.

Cylinder rod seal leak.

2.

Control valve spools do not return to NEUTRAL.

3.

The hydraulic system has a high operating temperature.

Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of components. Examples of visible contamination: 1.

Particles of metal or dirt in the oil.

2.

Air in the oil.

3.

The oil is dark and thick.

4.

The oil has an odor of burned oil.

5.

Water in the oil.

84522361 15/06/2011

A.10.A / 21

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Overview EH Drive Pattern Selector Switch L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

The control pattern switch is used to select the user grip control pattern for the functions of Ground Drive and Loader. Pattern setting will be remembered through key off. The control pattern switch, located in right-hand A-post below to the instrument cluster, allows the user to select between “ISO Pattern” and “ ‘H’ Pattern” control patterns by pressing the pattern switch button. The button has momentary positions on each the ISO and H positions and return to neutral when not pressed. ISO will be the left switch position and H will be the right switch position. The active operating mode is displayed by illuminating the corresponding LED on the button. An audible alarm will sound to indicate the switch selection has been made, accepted by the UCM. If the pattern change switch is activated when feature enable conditions are not met the machine will ignore the pattern change; the currently active pattern will remain illuminated and the machine will ignore the commanded pattern change. To allow pattern change, all feature enable conditions must be met before pushing the control pattern switch to the new pattern. The control pattern switch must be held for 3 seconds before a pattern change is accepted by the system. The new pattern LED will flash. Three sequential beeps occur whenever the new pattern is accepted. A message will also appear on the cluster screen will indicate the pattern is switched to “H” or “ISO” pattern. The control pattern switch always has an active control mode setting assigned. The following Conditions must be met to change setting: Ignition is in the ON position Operator must be properly seated Park brake must be active Operator restraint must be active Controls in neutral, including AUX switch

84522361 15/06/2011

A.10.A / 22

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of hydraulic valves L223, L225, L230, C232, C238

Component Name

Boom Over Ride Valve

Self Level Valve

Component ID (Reference Number)

Frame Location

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A) (10) - 60% valve PRIMARY HYDRAULIC only applicable POWER to L223, L225, L230, C232, and SYSTEM Hydraulic C238 models schematic frame 02 Valve assembly (A.10.A) (18)

Information (Tech Data)

Control valve - General specification of the EH and Mechanical boom override valve on all models (A.10.A) Control valve - General specification of the 60% self level valve on medium and large frame (G.30.A)

Ride Control Valve (9)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Control valve - General specification of the Ride Control Valve (A.10.A)

EH Control Valve

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Control valve - General specification of the EH Control Loader Valve for all models (A.10.A)

84522361 15/06/2011

A.10.A / 23

Functional

Diagnos- Service tic Information (Testing)

Control valve Remove Self level valve (G.30.A) Control valve Install Self level valve (G.30.A) Ride control valve Remove Glide Ride valve (H.40.B) Ride control valve Install Glide Ride valve (H.40.B) Control Charge valve pump Remove Pressure loader test (Machines control Equipped valve (EH) (H.20.B) with EH Controls) Control valve (A.10.A) Install loader control valve (EH) (H.20.B)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Name

Secondary Auxiliary Valve

Component ID (Reference Number) (13)

EH 2 Speed Track (3) Brake Valve

EH 2 Speed Brake (3) Valve

Pilot Operated Double Check Valve

(7)

Hydraulic Coupler Valve

(8)

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Two speed track drive assembly (A.10.A)

Control valve - General specification of the EH Control Loader Valve for all models (A.10.A)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Two speed drive assembly (A.10.A)

Control valve - General specification of the EH track brake valve on medium and large frame (D.32.C)

Control valve - General specification of the EH 2 speed brake valve on medium and large frame (D.32.C)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

84522361 15/06/2011

A.10.A / 24

Functional

Diagnos- Service tic Information (Testing)

Control valve Remove 2speed brake valve (D.32.C) Control valve Install 2speed brake valve (D.32.C) Control valve Remove 2speed brake valve (D.32.C) Control valve Install 2speed brake valve (D.32.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Name

High Flow Valve

Component Name

Boom Over Ride Valve

Self Level Valve

Component ID (Reference Number) (12)

Component ID (Reference Number)

Frame Location

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Frame Location

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) (10) - 60% valve PRIMARY only applicable to HYDRAULIC L223, L225, L230 POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) (18)

Ride Control Valve (9)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

Information (Tech Data)

Functional

Control valve Remove (A.16.A) Control valve Install (A.16.A)

Control valve - General specification High Flow Valve (A.10.A)

Information (Tech Data)

Control valve - General specification of the EH and Mechanical boom override valve on all models (A.10.A) Control valve - General specification of the 60% self level valve on medium and large frame (G.30.A)

Control valve - General specification of the Ride Control Valve (A.10.A)

84522361 15/06/2011

A.10.A / 25

Diagnos- Service tic Information (Testing)

Functional

Diagnos- Service tic Information (Testing)

Control valve Remove Self level valve (G.30.A) Control valve Install Self level valve (G.30.A) Ride control valve Remove Glide Ride valve (H.40.B) Ride control valve Install Glide Ride valve (H.40.B)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Name

Component ID (Reference Number)

Frame Location

Loader Mechanical (11) Foot Control Auxiliary Valve

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

Secondary Auxiliary Valve

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Single speed drive assembly (A.10.A)

(13)

Mechanical Single (3) Speed Brake Valve

Mechanical 2 (3) Speed Brake Valve

Pilot Operated Double Check Valve

(7)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Two speed drive assembly (A.10.A)

Information (Tech Data)

Control valve - General specification of Mechanical Foot Control Loader Valve (A.10.A)

Control valve - General specification of the Mechanical single speed brake valve on all frames except track models (D.32.C)

Control valve - General specification 2speed brake valve (D.32.C)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) 84522361 15/06/2011

A.10.A / 26

Functional

Diagnos- Service tic Information (Testing) Charge pump Pressure test (A.10.A)

Control valve Remove loader control valve (H.20.B) Control valve Install loader control valve (H.20.B)

Control valve Remove Brake valve (D.32.C) Control valve Install Brake valve (D.32.C) Control valve Remove Brake valve (D.32.C) Control valve Install Brake valve (D.32.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Name

Component ID (Reference Number)

Hydraulic Coupler Valve

(8)

High Flow Valve

(12)

Frame Location

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

Information (Tech Data)

Control valve - General specification High Flow Valve (A.10.A)

84522361 15/06/2011

A.10.A / 27

Functional

Diagnos- Service tic Information (Testing)

Control valve Remove (A.16.A) Control valve Install (A.16.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of hydraulic valves L218, L220, C227

Component Name

Boom Over Ride Valve

Component ID (Reference Number)

(18)

Frame Location

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) For C227 PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Information (Tech Data)

Control valve - General specification of the EH and Mechanical boom override valve on all models (A.10.A)

84522361 15/06/2011

A.10.A / 28

Functional

DiagService nostic Information (Testing)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Name

Self Level Valve

Component ID (Reference Number)

Frame Location

Information (Tech Data)

(10) - 40% valve PRIMARY only applicable to HYDRAULIC POWER L218 models SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

Control valve - General specification of the 40% self level valve on medium frame (G.30.A)

(10) - 60% valve PRIMARY only applicable to HYDRAULIC POWER L220 models SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

Control valve - General specification of the 60% self level valve on medium and large frame (G.30.A)

(10) - 50% valve PRIMARY only applicable to HYDRAULIC POWER C227 models SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Control valve - General specification of the 50% self level valve on medium frame (G.30.A)

84522361 15/06/2011

A.10.A / 29

Functional

DiagService nostic Information (Testing) Control valve Remove Self level valve (G.30.A) Control valve Install Self level valve (G.30.A) Control valve Remove Self level valve (G.30.A) Control valve Install Self level valve (G.30.A) Control valve Remove Self level valve (G.30.A) Control valve Install Self level valve (G.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Name

Glide Ride Valve

EH Control Valve

Component ID (Reference Number)

(9)

Frame Location

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

For C227 PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) For C227 PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Information (Tech Data)

Functional

DiagService nostic Information (Testing) Ride control valve Remove Glide Ride valve (H.40.B) Ride control valve Install Glide Ride valve (H.40.B)

Control valve - General specification of the Ride Control Valve (A.10.A)

Control valve - General specification of the EH Control Loader Valve for all models (A.10.A)

84522361 15/06/2011

A.10.A / 30

Charge pump Pressure test (Machines Equipped with EH Controls) (A.10.A)

Control valve Remove loader control valve (EH) (H.20.B) Control valve Install loader control valve (EH) (H.20.B)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Name

Second Auxiliary Valve

Component ID (Reference Number)

(13)

EH 2 Speed Track (3) Brake Valve

Frame Location

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) For C227 PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Two speed track drive assembly (A.10.A)

Information (Tech Data)

Control valve - General specification of the EH track brake valve on medium and large frame (D.32.C)

84522361 15/06/2011

A.10.A / 31

Functional

DiagService nostic Information (Testing)

Control valve Remove 2speed brake valve (D.32.C) Control valve Install 2speed brake valve (D.32.C) For C227 Control valve Remove EH 2speed brake valve (D.32.C) Control valve Install EH 2speed brake valve (D.32.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Name

Component ID (Reference Number)

Frame Location

EH 2 Speed Brake (3) Does not apply PRIMARY HYDRAULIC Valve to Track models POWER SYSTEM Hydraulic schematic frame 01 Two speed drive assembly (A.10.A)

Pilot Operated Double Check Valve

(7)

Hydraulic Coupler (8) Valve

Information (Tech Data)

Control valve - General specification of the EH 2 speed brake valve on medium and large frame (D.32.C)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) For C227 PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) For C227 PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

84522361 15/06/2011

A.10.A / 32

Functional

DiagService nostic Information (Testing) Control valve Remove 2speed brake valve (D.32.C) Control valve Install 2speed brake valve (D.32.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Name

High Flow Valve

Component ID (Reference Number)

(12)

Frame Location

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) For C227 PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Information (Tech Data)

Control valve - General specification High Flow Valve (A.10.A)

84522361 15/06/2011

A.10.A / 33

Functional

DiagService nostic Information (Testing) Control valve Remove (A.16.A) Control valve Install (A.16.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Name

Boom Over Ride Valve

Self Level Valve

Glide Ride Valve

Component ID (Reference Number)

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) (10) - 40% valve PRIMARY only applicable to HYDRAULIC POWER L218 models SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

Control valve - General specification of the EH and Mechanical boom override valve on all models (A.10.A)

(10) - 60% valve PRIMARY only applicable to HYDRAULIC POWER L220 models SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

Control valve - General specification of the 60% self level valve on medium and large frame (G.30.A)

(18)

(9)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

Control valve - General specification of the 40% self level valve on medium frame (G.30.A)

Control valve - General specification of the Ride Control Valve (A.10.A)

84522361 15/06/2011

A.10.A / 34

Functional

DiagService nostic Information (Testing)

Control valve Remove Self level valve (G.30.A) Control valve Install Self level valve (G.30.A) Control valve Remove Self level valve (G.30.A) Control valve Install Self level valve (G.30.A) Ride control valve Remove Glide Ride valve (H.40.B) Ride control valve Install Glide Ride valve (H.40.B)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Name

Component ID (Reference Number)

Frame Location

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

Loader Mechanical Foot Control Valve

(11) All models with foot controls

Loader Mechanical Hand Control Valve

PRIMARY (11) All models with hand controls HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

Secondary Auxiliary Valve

(13)

Mechanical Single (3) Speed Brake Valve

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Single speed drive assembly (A.10.A)

Information (Tech Data)

Functional

DiagService nostic Information (Testing)

Control valve - General specification of Mechanical Foot Control Loader Valve (A.10.A)

Charge pump Pressure test (A.10.A)

Control valve - General specification Mechanical Hand Control Loader valve on all models (A.10.A)

Charge pump Pressure test (A.10.A)

Control valve - General specification of the Mechanical single speed brake valve on all frames except track models (D.32.C)

84522361 15/06/2011

A.10.A / 35

Control valve Remove loader control valve (H.20.B) Control valve Install loader control valve (H.20.B) Control valve Remove loader control valve (H.20.B) Control valve Install loader control valve (H.20.B)

Control valve Remove Brake valve (D.32.C) Control valve Install Brake valve (D.32.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Name

Component ID (Reference Number)

(3) 2 Speed Mechanical Brake Valve

Pilot Operated Double Check Valve

(7)

Hydraulic Coupler (8) Valve

High Flow Valve

(12)

Frame Location

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Two speed drive assembly (A.10.A)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

Information (Tech Data)

Functional

DiagService nostic Information (Testing)

Control valve - General specification 2speed brake valve (D.32.C)

Control valve Remove 2speed brake valve (D.32.C) Control valve Install 2speed brake valve (D.32.C)

Control valve - General specification High Flow Valve (A.10.A)

Control valve Remove (A.16.A) Control valve Install (A.16.A)

84522361 15/06/2011

A.10.A / 36

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of hydraulic valves L213, L215

Component Component Name ID (Reference Number) Boom Over Ride (18) Valve

Self Level Valve

(10) - 48% valve

Glide Ride Valve

(9)

EH Single Speed (3) Brake Valve

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Control valve - General specification of the EH and Mechanical boom override valve on all models (A.10.A)

Control valve - General specification of the 48% self level valve on small frame (G.30.A)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Control valve - General specification of the Ride Control Valve (A.10.A)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Single speed drive assembly (A.10.A)

Control valve - General specification of the EH single speed brake valve on small frame (D.32.C)

84522361 15/06/2011

A.10.A / 37

Functional

Diagnos- Service tic Information (Testing)

Control valve Remove Self level valve (G.30.A) Control valve Install Self level valve (G.30.A) Ride control valve Remove Glide Ride valve (H.40.B) Ride control valve Install Glide Ride valve (H.40.B) Control valve Remove EH brake valve (D.32.C) Control valve Install EH brake valve (D.32.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Component Name ID (Reference Number) EH Control Loader Valve

(11)

Component Component Name ID (Reference Number) Boom Over Ride (18) Valve

Self Level Valve

(10) - 48% valve

Glide Ride Control Valve

(9)

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Control valve - General specification of the EH Control Loader Valve for all models (A.10.A)

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Control valve - General specification of the EH and Mechanical boom override valve on all models (A.10.A)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Control valve - General specification of the Ride Control Valve (A.10.A)

Control valve - General specification of the 48% self level valve on small frame (G.30.A)

84522361 15/06/2011

A.10.A / 38

Functional

Diagnos- Service tic Information (Testing) Charge pump Pressure test (Machines Equipped with EH Controls) (A.10.A)

Functional

Control valve Remove loader control valve (H.20.B) Control valve Install loader control valve (H.20.B)

Diagnos- Service tic Information (Testing)

Control valve Remove Self level valve (G.30.A) Control valve Install Self level valve (G.30.A) Ride control valve Remove Glide Ride valve (H.40.B) Ride control valve Install Glide Ride valve (H.40.B)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Component Name ID (Reference Number)

Frame Location

Information (Tech Data)

Functional

Diagnos- Service tic Information (Testing)

Foot Control Loader Valve

(11)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Control valve - General specification of Mechanical Foot Control Loader Valve (A.10.A)

Charge pump Pressure test (A.10.A)

Hand Control Loader Valve

(11)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Control valve - General specification Mechanical Hand Control Loader valve on all models (A.10.A)

Charge pump Pressure test (A.10.A)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Single speed drive assembly (A.10.A)

Control valve - General specification of the Mechanical single speed brake valve on all frames except track models (D.32.C)

(3) Single Speed Mechanical Brake Valve

84522361 15/06/2011

A.10.A / 39

Control valve Remove loader control valve (H.20.B) Control valve Install loader control valve (H.20.B) Control valve Remove loader control valve (H.20.B) Control valve Install loader control valve (H.20.B) Control valve Remove Brake valve (D.32.C) Control valve Install Brake valve (D.32.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of pumps of large frame models L223, L225, L230, C232, C238

Component Component Name ID (Reference Number)

Frame Location

Information (Tech Data)

46cc EH (4) applicable Hydrostatic to L223, L225, Pump A20VG - L230 models ET

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly (A.10.A)

46cc EH (4) applicable Hydrostatic to C232, C238 Pump A20VG - models ET

46cc (2) applicable Enhanced to L230. High Flow (EHF) Hydrostatic Pump A20VG ET (no charge pump), used with 53cc EHF Hydrostatic (High Pressure) Pump - A10VG - EP 34.1cc (16) Auxiliary. Gear Pump (Standard)

Diagnostic Information (Testing)

Service

Pump - General specification 46cc EH Hydrostatic pump (C.20.F)

TRANSMISSION Hydrostatic - Troubleshooting (C.20.F)

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed track drive assembly (A.10.A)

Pump - General specification 46cc EH Hydrostatic pump (C.20.F)

TRANSMISSION Hydrostatic - Troubleshooting (C.20.F)

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Enhanced high flow option (A.10.A)

Pump - General specification 46cc EHF Hydrostatic pump, used with large frame models. (C.20.F)

TRANSMISSION Hydrostatic - Troubleshooting (C.20.F)

Pump - Remove EH hydrostatic pump (C.20.F) Pump - Install EH hydrostatic pump (C.20.F) Pump - Remove EH hydrostatic pump (C.20.F) Pump - Install EH hydrostatic pump (C.20.F) Pump - Remove EH hydrostatic pump (C.20.F) Pump - Install EH hydrostatic pump (C.20.F)

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly (A.10.A)

PRIMARY HYDRAULIC POWER SYSTEM - General specification of the 34.1cc gear pump (A.10.A)

84522361 15/06/2011

A.10.A / 40

Functional

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Component Name ID (Reference Number) High Flow 18.3cc Gear Pump (Optional)

(17)

High Flow 18.3cc Gear Pump (Optional)

(17)

High Flow 12.5cc (Optional)

(17)

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM - General specification for the 34.1cc Gear pump with high flow 18.3cc. (A.10.A) PRIMARY PRIMARY HYDRAULIC HYDRAULIC POWER SYSTEM POWER SYSTEM - Hydraulic - General schematic specification frame 03 Valve for the 34.1cc assembly Gear pump (A.10.A) with high flow 18.3cc. (A.10.A) PRIMARY PRIMARY HYDRAULIC HYDRAULIC POWER SYSTEM POWER SYSTEM - Hydraulic - General schematic specification frame 03 Valve for the 34.1cc assembly Gear pump (A.10.A) with high flow 12.5cc. (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly (A.10.A)

84522361 15/06/2011

A.10.A / 41

Functional

Diagnostic Information (Testing)

Service

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Component Name ID (Reference Number)

Frame Location

Information (Tech Data)

46cc (4) models Hydrostatic equipped with Tandem Pump 2speed MDC Bushed

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly (A.10.A)

Pump - General specification 46cc Hydrostatic tandem pump, used with large frame models. (C.20.F)

46cc (4) models Hydrostatic equipped with Tandem Pump single speed MDC Bushed

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Single speed drive assembly (A.10.A)

Pump - General specification 46cc Hydrostatic tandem pump, used with large frame models. (C.20.F)

34.1cc Auxiliary. Gear Pump (Standard)

(16)

High Flow 18.3cc Gear Pump (Optional)

(17)

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A)

PRIMARY HYDRAULIC POWER SYSTEM - General specification of the 34.1cc gear pump (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM - General specification for the 34.1cc Gear pump with high flow 18.3cc. (A.10.A)

84522361 15/06/2011

A.10.A / 42

Functional

Diagnostic Information (Testing)

Service

Pump Remove mechanical hydrostatic pump (C.20.F) Pump Install mechanical hydrostatic pump (C.20.F) TRANSMIS- Pump SION Hydro- Remove static - Trou- mechanbleshooting ical hydrostatic (C.20.F) pump (C.20.F) Pump Install mechanical hydrostatic pump (C.20.F) TRANSMISSION Hydrostatic - Troubleshooting (C.20.F)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Component Name ID (Reference Number) High Flow 12.5cc (Optional)

(17)

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A)

PRIMARY HYDRAULIC POWER SYSTEM - General specification for the 34.1cc Gear pump with high flow 12.5cc. (A.10.A)

84522361 15/06/2011

A.10.A / 43

Functional

Diagnostic Information (Testing)

Service

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of pumps on medium frame models L218, L220, C227

Component Component Name ID (Reference Number)

Frame Location

Informa- Functional Diagnostic Infortion (Tech mation Data) (Testing)

46cc EH (4) applicable Hydrostatic to C227 Pump A20VG - models only ET

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Two speed track drive assembly (A.10.A)

Pump - General specification 46cc EH Hydrostatic pump (C.20.F)

35cc EH (4) applicable Hydrostatic to L218, L220 Pump A20VG - models only ET

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Two speed drive assembly (A.10.A)

Pump - General specification 35cc EH Hydrostatic pump, used with small and medium frame models. (C.20.F)

24.9cc (16) applicable PRIMARY HYDRAULIC Auxiliary Pump to L218, L220 POWER SYSTEM (Standard) Hydraulic schematic models. frame 03 Valve assembly (A.10.A)

PRIMARY HYDRAULIC POWER SYSTEM - General specification for the 24.9cc Gear Pump (A.10.A)

84522361 15/06/2011

A.10.A / 44

Service

Pump - Remove EH hydrostatic pump (C.20.F) Pump - Install EH hydrostatic pump (C.20.F) Pump TRANS- ReMISSION move HydroEH hystatic dro- Troubleshoot- static ing (C.20.F) pump (C.20.F) Pump - Install EH hydrostatic pump (C.20.F)

TRANSMISSION Hydrostatic - Troubleshooting (C.20.F)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Component Name ID (Reference Number)

Frame Location

Informa- Functional Diagnostic Infortion (Tech mation Data) (Testing)

PRIMARY HYDRAULIC POWER SYSTEM - General specification of the 24.9cc Gear pump with high flow 12.5cc pump (A.10.A) PRIMARY 34.1cc (16) applicable PRIMARY HYDRAULIC HYDRAULIC Auxiliary. to C227 model. POWER SYSTEM POWER Gear Pump Hydraulic schematic (Standard) frame 02 Valve assembly SYSTEM - General (A.10.A) specification of the 34.1cc gear pump (A.10.A) PRIMARY High Flow 34.1 (17) PRIMARY HYDRAULIC HYDRAULIC / 12.5 Pump POWER SYSTEM POWER (Optional) Hydraulic schematic frame 03 Valve assembly SYSTEM - General (A.10.A) specificaFor C227 tion for PRIMARY HYDRAULIC the 34.1cc POWER SYSTEM Gear pump Hydraulic schematic frame 03 Enhanced high with high flow 18.3cc. flow option (A.10.A) (A.10.A)

High Flow 24.9 (17) / 12.5cc Pump (Optional)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

84522361 15/06/2011

A.10.A / 45

Service

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Functional

Diagnostic Service Information (Testing)

Frame Location

Information (Tech Data)

35cc (4) Hydrostatic Tandem Pump DDC

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Single speed drive assembly (A.10.A)

Pump - General specification Mechanical controls 35cc Hydrostatic tandem pump, used with small and medium frame models. (C.20.F)

TRANSMISSION Hydrostatic - Troubleshooting (C.20.F)

35cc (4) Hydrostatic Tandem Pump DDC

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Two speed drive assembly (A.10.A)

Pump - General specification Mechanical controls 35cc Hydrostatic tandem pump, used with small and medium frame models. (C.20.F)

TRANSMISSION Hydrostatic - Troubleshooting (C.20.F)

24.9cc (16) Auxiliary Pump (Standard)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 03 Valve assembly (A.10.A)

PRIMARY HYDRAULIC POWER SYSTEM - General specification for the 24.9cc Gear Pump (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM - General specification of the 24.9cc Gear pump with high flow 12.5cc pump (A.10.A)

Component Component Name ID (Reference Number)

High Flow 24.9 / 12.5cc Gear Pump (Optional)

(17)

84522361 15/06/2011

A.10.A / 46

Pump Remove mechanical hydrostatic pump (C.20.F) Pump Install mechanical hydrostatic pump (C.20.F) Pump Remove mechanical hydrostatic pump (C.20.F) Pump Install mechanical hydrostatic pump (C.20.F)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of pumps on small frame models L213, L215

Frame Location

Information (Tech Data)

35cc (4) Hydrostatic Tandem Pump DDC

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Single speed drive assembly (A.10.A)

Pump - General specification Mechanical controls 35cc Hydrostatic tandem pump, used with small and medium frame models. (C.20.F)

20.4 cc Auxiliary Gear Pump (Standard)

(16)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

35cc EH tandem pump

(4)

Component Component Name ID (Reference Number)

PRIMARY HYDRAULIC POWER SYSTEM - General specification of the 20.4cc gear pump (A.10.A) PRIMARY HYDRAULIC Pump - General specification POWER SYSTEM 35cc EH Hydraulic schematic frame 01 Single speed Hydrostatic drive assembly (A.10.A) pump, used with small and medium frame models. (C.20.F)

84522361 15/06/2011

A.10.A / 47

Functional

DiagService nostic Information (Testing) TRANSMISSION Hydrostatic - Troubleshooting (C.20.F)

Pump Remove mechanical hydrostatic pump (C.20.F) Pump - Install mechanical hydrostatic pump (C.20.F)

TRANSMISSION Hydrostatic - Troubleshooting (C.20.F)

Pump Remove EH hydrostatic pump (C.20.F) Pump Install EH hydrostatic pump (C.20.F)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of cylinders on small frame models L213, L215

Component Component Name ID (Reference Number) Loader Arm - Hydraulic Bucket Tip Cylinder

Left hand tip cylinder (5) Right hand tip cylinder (6)

Loader Arm Lift Cylinder

Left hand lift cylinder (3) Right hand lift cylinder (4)

Component Component Name ID (Reference Number) Loader Arm - Hydraulic Bucket Tip Cylinder

Left hand tip cylinder (5) Right hand tip cylinder (6)

Loader Arm Lift Cylinder

Left hand lift cylinder (3) Right hand lift cylinder (4)

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Frame Location

Diagnostic Information (Testing)

Service

SINGLE ARM Lift Not function (Incorrect or No Loader Function) (H.40.B)

Cylinder Remove lift arm cylinder (H.40.B) Cylinder Install lift arm cylinder (H.20.B)

Diagnostic Information (Testing)

Service

SINGLE ARM Lift Not function (Incorrect or No Loader Function) (H.40.B)

Cylinder Remove lift arm cylinder (H.40.B) Cylinder Install lift arm cylinder (H.20.B)

Cylinder - General specification (G.20.A)

Cylinder - General specification (G.10.A)

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Valve assembly (A.10.A)

Functional

Functional

Cylinder - General specification (G.20.A)

Cylinder - General specification (G.10.A)

84522361 15/06/2011

A.10.A / 48

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of cylinders on medium frames L218, L220, C227

Component Component Name ID (Reference Number) Loader Arm - Hydraulic Bucket Tip Cylinder

Left hand tip cylinder (5) - Right hand tip cylinder (6) applicable to C227 model

Loader Arm Lift Cylinder

Left hand lift cylinder (3) - Right hand lift cylinder (4) applicable to C227 model

Loader Arm - Hydraulic Bucket Tip Cylinder

Left hand tip cylinder (5) - Right hand tip cylinder (6) applicable to L218 model

Loader Arm Lift Cylinder

Left hand lift cylinder (3) applicable to L218 and 220 models

Loader Arm Lift Cylinder

Right hand lift cylinder (4) applicable to L218 and 220 models

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Cylinder - General specification (G.20.A)

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Cylinder - General specification (G.10.A)

Functional

Diagnostic Information (Testing)

Service

Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.20.B)

Cylinder - General specification (G.20.A)

Cylinder - General specification (G.10.A)

PRIMARY Cylinder - General HYDRAULIC specification POWER SYSTEM (G.10.A) - Hydraulic schematic frame 03 Valve assembly (A.10.A)

84522361 15/06/2011

A.10.A / 49

Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.40.B) Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.40.B)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Component Name ID (Reference Number)

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Cylinder - General specification (G.20.A)

Loader Arm - Hydraulic Bucket Tip Cylinder

Left hand tip cylinder (5) - Right hand tip cylinder (6) applicable to L220 model

Loader Arm Lift Cylinder

Left hand lift cylinder (3) applicable to L220 model

Loader Arm Lift Cylinder

Right hand lift cylinder (4) applicable to L220 model

PRIMARY Cylinder - General HYDRAULIC specification POWER SYSTEM (G.10.A) - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Hydraulic Coupler Cylinders

Left hand coupler cylinder (1) - Right hand coupler cylinder (2)

PRIMARY Cylinder - General HYDRAULIC specification POWER SYSTEM (J.80.C) - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Cylinder - General specification (G.10.A)

84522361 15/06/2011

A.10.A / 50

Functional

Diagnostic Information (Testing)

Service

Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.40.B) Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.40.B)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Component Name ID (Reference Number)

Frame Location

Information (Tech Data)

Loader Arm - Hydraulic Bucket Tip Cylinder

Left hand tip cylinder (5) - Right hand tip cylinder (6) applicable to C227 model

PRIMARY Cylinder - General HYDRAULIC specification POWER SYSTEM (G.20.A) - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Loader Arm Lift Cylinder

Left hand lift cylinder (3) - Right hand lift cylinder (4) applicable to C227 model

PRIMARY Cylinder - General HYDRAULIC specification POWER SYSTEM (G.10.A) - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Loader Arm - Hydraulic Bucket Tip Cylinder

Left hand tip cylinder (5) - Right hand tip cylinder (6) applicable to L218 model

Loader Arm Lift Cylinder

Left hand lift cylinder (3) applicable to L218 model

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Loader Arm Lift Cylinder

Right hand lift cylinder (4) applicable to L218 model

PRIMARY Cylinder - General HYDRAULIC specification POWER SYSTEM (G.10.A) - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Loader Arm - Hydraulic Bucket Tip Cylinder

Left hand tip cylinder (5) - Right hand tip cylinder (6) applicable to L220 model

PRIMARY Cylinder - General HYDRAULIC specification POWER SYSTEM (G.20.A) - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Functional

Diagnostic Information (Testing)

Service

Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.20.B) Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.20.B)

Cylinder - General specification (G.20.A)

Cylinder - General specification (G.10.A)

84522361 15/06/2011

A.10.A / 51

Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.40.B) Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.40.B)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Component Name ID (Reference Number)

Frame Location

Information (Tech Data)

Loader Arm Lift Cylinder

Left hand lift cylinder (3) applicable to L220 model

PRIMARY Cylinder - General HYDRAULIC specification POWER SYSTEM (G.10.A) - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Loader Arm Lift Cylinder

Right hand lift cylinder (4) applicable to L220 model

PRIMARY Cylinder - General HYDRAULIC specification POWER SYSTEM (G.10.A) - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Hydraulic Coupler Cylinders

Left hand coupler cylinder (1) - Right hand coupler cylinder (2)

PRIMARY Cylinder - General HYDRAULIC specification POWER SYSTEM (J.80.C) - Hydraulic schematic frame 03 Valve assembly (A.10.A)

84522361 15/06/2011

A.10.A / 52

Functional

Diagnostic Information (Testing)

Service

Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.40.B) Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.40.B)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of cylinders on large frame models L223, L225, L230, C232, C238

Frame Location

Information (Tech Data)

Left hand tip cylinder (5) - Right hand tip cylinder (6) applicable to L223, L225, L230, C232, C238 models Left hand lift cylinder (3) applicable to L223, L225, L230, C232, C238 models

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly (A.10.A)

Cylinder - General specification (G.20.A)

Right hand lift cylinder (4) applicable to L223, L225, L230, C232, C238 models

PRIMARY Cylinder - General HYDRAULIC specification POWER SYSTEM (G.10.A) - Hydraulic schematic frame 02 Valve assembly (A.10.A)

Component Component Name ID (Reference Number) Loader Arm - Hydraulic Bucket Tip Cylinder

Loader Arm Lift Cylinder

Loader Arm Lift Cylinder

Component Component Name ID (Reference Number) Loader Arm - Hydraulic Bucket Tip Cylinder

Loader Arm Lift Cylinder

Left hand tip cylinder (5) - Right hand tip cylinder (6) applicable to L223, L225, L230, C232, C238 models Left hand lift cylinder (3) applicable to L223, L225, L230, C232, C238 models

Functional

Diagnostic Information (Testing)

Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.40.B) Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.40.B)

Cylinder - General specification (G.10.A)

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly (A.10.A)

Cylinder - General specification (G.20.A)

Cylinder - General specification (G.10.A)

84522361 15/06/2011

A.10.A / 53

Service

Functional

Diagnostic Information (Testing)

Service

Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.40.B)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Component Name ID (Reference Number) Loader Arm Lift Cylinder

Right hand lift cylinder (4) applicable to L223, L225, L230, C232, C238 models

Frame Location

Information (Tech Data)

PRIMARY Cylinder - General HYDRAULIC specification POWER SYSTEM (G.10.A) - Hydraulic schematic frame 03 Valve assembly (A.10.A)

84522361 15/06/2011

A.10.A / 54

Functional

Diagnostic Information (Testing)

Service

Cylinder - Remove lift arm cylinder (H.40.B) Cylinder - Install lift arm cylinder (H.40.B)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of hydraulic motors L223, L225, L230, C232, C238

Component Component Name ID (Reference Number)

Frame Location

Informa- Functional Diagnostic Information tion (Tech (Testing) Data)

PRIMARY EH Track Left Hand Drive, 2 Speed Motor (1), Right HYDRAULIC Motor Hand Motor (2) POWER SYSTEM Hydraulic schematic frame 01 Two speed track drive assembly (A.10.A) PRIMARY EH 470cc Left Hand 2 Speed Motor (1), Right HYDRAULIC Hydrostatic Hand Motor (2) POWER SYSTEM Motor Hydraulic schematic frame 01 Two speed drive assembly (A.10.A)

Component Component Name ID (Reference Number)

Motor Remove track drive motor (C.20.F) Motor Install track drive motor (C.20.F)

Motor General specification for EH and Mechanical 470cc 2 speed motor on medium and large frames (C.20.F)

Motor Remove (C.20.F) Motor - Install (C.20.F)

Motor General specification for EH and Mechanical 470cc 2 speed motor on medium and large frames (C.20.F) Motor PRIMARY Left Hand General Motor (1), Right HYDRAULIC specification Hand Motor (2) POWER for SYSTEM mechanical Hydraulic schematic frame 470cc single 02 Single speed speed motor drive assembly on medium and large (A.10.A) frames (C.20.F)

Mechanical Left Hand 470cc 2 Speed Motor (1), Right Hydrostatic Hand Motor (2) Motor

Mechanical 470cc Single Speed Hydrostatic Motor

Motor General specification for track drive 2 speed motor on medium and large frames (C.20.F)

Informa- Functional Diagnostic Information tion (Tech (Testing) Data)

Frame Location

Service

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Two speed drive assembly (A.10.A)

84522361 15/06/2011

A.10.A / 55

Service

Motor Remove (C.20.F) Motor - Install (C.20.F)

Motor Remove (C.20.F) Motor - Install (C.20.F)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of hydraulic motors L218, L220

Component Component Name ID (Reference Number) 325cc EH 2 Speed Motor

470cc EH 2 Speed Hydrostatic Motor

EH 2 Speed Track Drive Motor

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Two speed drive assembly (A.10.A) PRIMARY Left Hand HYDRAULIC Motor (1) POWER Right Hand SYSTEM Motor (2) Hydraulic schematic frame 01 Two speed drive assembly (A.10.A) For track units PRIMARY HYDRAULIC only POWER Left Hand SYSTEM Motor (1) Hydraulic Right Hand schematic Motor (2) frame 01 Two speed track drive assembly (A.10.A) Left Hand Motor (1) Right Hand Motor (2)

Functional

Diagnostic Information (Testing)

Service

Motor - General specification for 325cc 2 speed motor on medium frames (C.20.F)

Motor Remove (C.20.F) Motor Install (C.20.F)

Motor - General specification for EH and Mechanical 470cc 2 speed motor on medium and large frames (C.20.F)

Motor Remove (C.20.F) Motor Install (C.20.F)

Motor - General specification for track drive 2 speed motor on medium and large frames (C.20.F)

Motor Remove track drive motor (C.20.F) Motor Install track drive motor (C.20.F)

84522361 15/06/2011

A.10.A / 56

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Component Component Name ID (Reference Number) 325cc Mechanical Single Speed Motor

Left Hand Motor (1) Right Hand Motor (2)

325cc Mechanical2 Speed Motor

Left Hand Motor (1) Right Hand Motor (2)

470cc Mechanical Single Speed Hydrostatic Motor

Left Hand Motor (1) Right Hand Motor (2) (SR200)

470cc Mechanical 2 Speed Hydrostatic Motor

Left Hand Motor (1) Right Hand Motor (2)

Functional

Diagnostic Information (Testing)

Frame Location

Information (Tech Data)

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Single speed drive assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Single speed drive assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Single speed drive assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Two speed drive assembly (A.10.A)

Motor - General specification for EH and Mechanical 325cc single speed motor on medium and small frame models (C.20.F)

Motor Remove (C.20.F) Motor Install (C.20.F)

Motor - General specification for EH and Mechanical 325cc single speed motor on medium and small frame models (C.20.F)

Motor Remove (C.20.F) Motor Install (C.20.F)

Motor - General specification for mechanical 470cc single speed motor on medium and large frames (C.20.F)

Motor Remove (C.20.F) Motor Install (C.20.F)

Motor - General specification for EH and Mechanical 470cc 2 speed motor on medium and large frames (C.20.F)

Motor Remove (C.20.F) Motor Install (C.20.F)

84522361 15/06/2011

A.10.A / 57

Service

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of hydraulic motors on small frame models L213, L215

Component Component Name ID (Reference Number) 325cc Mechanical Single Speed Motor

Left Hand Motor (1) Right Hand Motor (2)

325cc EH Single Speed Motor

Left Hand Motor (1) Right Hand Motor (2)

Frame Location

PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 02 Single speed drive assembly (A.10.A) PRIMARY HYDRAULIC POWER SYSTEM Hydraulic schematic frame 01 Single speed drive assembly (A.10.A)

Information (Tech Data)

Functional

Diagnostic Information (Testing)

Service

Motor - General specification for EH and Mechanical 325cc single speed motor on medium and small frame models (C.20.F)

Motor Remove (C.20.F) Motor - Install (C.20.F)

Motor - General specification for EH and Mechanical 325cc single speed motor on medium and small frame models (C.20.F)

Motor Remove (C.20.F) Motor - Install (C.20.F)

84522361 15/06/2011

A.10.A / 58

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

84522361 15/06/2011

A.10.A / 59

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls

(1) (2) (A)

Right hand motor Left hand motor To case drain tube

(3) (4) (B)

(C)

Crossover pump suction line

(D)

84522361 15/06/2011

A.10.A / 60

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102461A

1

84522361 15/06/2011

A.10.A / 61

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Single speed drive assembly L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

(1) (2) (A) (C)

84522361 15/06/2011

A.10.A / 62

Right hand motor Left hand motor To case drain tube Crossover pump suction line

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102463A

1

84522361 15/06/2011

A.10.A / 63

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 64

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from charge pump

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102454B

1

84522361 15/06/2011

A.10.A / 65

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 04 Enhanced high flow option L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

(1) (Pin) (X)

84522361 15/06/2011

A.10.A / 66

High flow pump (2) Flow to EH loader valve - PIN (E) main Reservoir suction line (B)

Hydrostatic pump Charge pump suction line To case drain tube

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

23112911

1

84522361 15/06/2011

A.10.A / 67

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

(1) (2) (A) (C)

84522361 15/06/2011

A.10.A / 68

Right hand motor Left hand motor To case drain tube Crossover pump suction line

(3) (4) (B) (D)

Brake / shift manifold 2 spd Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102459A

1

84522361 15/06/2011

A.10.A / 69

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Single speed drive assembly L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

(1) (2) (A) (C)

84522361 15/06/2011

A.10.A / 70

Right hand motor Left hand motor To case drain tube Crossover pump suction line

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102457A

1

84522361 15/06/2011

A.10.A / 71

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 72

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from charge pump

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102449A

1

84522361 15/06/2011

A.10.A / 73

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed track drive assembly C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

(1) (2) (A) (C) (E)

84522361 15/06/2011

A.10.A / 74

Right hand motor Left hand motor To case drain tube Crossover pump suction line Pilot control pressure from brake / shift / EH valve

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

23112910

1

84522361 15/06/2011

A.10.A / 75

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 76

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from brake / shift / EH valve

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102455 C

1

84522361 15/06/2011

A.10.A / 77

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Enhanced high flow option L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

(1) (Pin) (X)

84522361 15/06/2011

A.10.A / 78

High flow pump (2) Flow to EH loader valve - PIN (E) main Reservoir suction line (B)

Hydrostatic pump Charge pump suction line To case drain tube

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102430B

1

84522361 15/06/2011

A.10.A / 79

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly L223, L225, L230

(1) (2) (A) (C) (E)

84522361 15/06/2011

A.10.A / 80

Right hand motor Left hand motor To case drain tube Crossover pump suction line Pilot control pressure from brake / shift / EH valve

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102462A

1

84522361 15/06/2011

A.10.A / 81

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 82

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from brake / shift / EH valve

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102455 C

1

84522361 15/06/2011

A.10.A / 83

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Enhanced high flow option L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

(1) (Pin) (X)

84522361 15/06/2011

A.10.A / 84

High flow pump (2) Flow to EH loader valve - PIN (E) main Reservoir suction line (B)

Hydrostatic pump Charge pump suction line To case drain tube

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102430B

1

84522361 15/06/2011

A.10.A / 85

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly L218 Electro hydraulic controls, L220 Electro hydraulic controls

(1) (2) (A) (C) (E)

84522361 15/06/2011

A.10.A / 86

Right hand motor Left hand motor To case drain tube Crossover pump suction line Pilot control pressure from brake / shift / EH valve

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102460A

1

84522361 15/06/2011

A.10.A / 87

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Single speed drive assembly L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

(1) (2) (A) (C)

84522361 15/06/2011

A.10.A / 88

Right hand motor Left hand motor To case drain tube Crossover pump suction line

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102458A

1

84522361 15/06/2011

A.10.A / 89

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 90

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from charge pump

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102450A

1

84522361 15/06/2011

A.10.A / 91

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Single speed drive assembly L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls

(1) (2) (A) (C)

84522361 15/06/2011

A.10.A / 92

Right hand motor Left hand motor To case drain tube Crossover pump suction line

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102457A

1

84522361 15/06/2011

A.10.A / 93

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 94

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from charge pump

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102449A

1

84522361 15/06/2011

A.10.A / 95

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Single speed drive assembly L213 Electro hydraulic controls, L215 Electro hydraulic controls

(1) (2) (A) (C)

84522361 15/06/2011

A.10.A / 96

Right hand motor Left hand motor To case drain tube Crossover pump suction line

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102458A

1

84522361 15/06/2011

A.10.A / 97

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly L213 Electro hydraulic controls, L215 Electro hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 98

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from charge pump

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102450A

1

84522361 15/06/2011

A.10.A / 99

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

84522361 15/06/2011

A.10.A / 100

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control valve - Overview Loader Lift Control - Overview The loader arm can be raised and lowered by the operator with proportional flow control to the loader arm cylinders via the dedicated valve section. In ISO mode, (EH only) the loader arm is raised by pulling the right joystick handle rearward toward the operator and lowered by pushing the handle forward away from the operator. The further the joystick is actuated away from its spring-centred neutral position, the faster the loader arm moves. In H-Pattern (EH and mechanical hand controls) the loader arm is raised by pushing the left joystick handle to the left and lowered by pulling the handle towards to the right. The further the joystick is actuated away from its spring-centred neutral position, the faster the loader arm moves. For Foot Controls, the loader arm is raised by pushing down on the back of the left foot pedal and lowered by pushing the left foot pedal forward. The further the pedal is actuated away from its spring centered neutral position, the faster the loader arm moves. The loader arm can be controlled only if all of the following conditions are met: Operator Present Operator restraint engaged The door is closed (if equipped) The ignition is on Hydraulics is enabled

84522361 15/06/2011

A.10.A / 101

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102461A

1

84522361 15/06/2011

A.10.A / 61

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Single speed drive assembly L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

(1) (2) (A) (C)

84522361 15/06/2011

A.10.A / 62

Right hand motor Left hand motor To case drain tube Crossover pump suction line

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102463A

1

84522361 15/06/2011

A.10.A / 63

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 64

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from charge pump

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102454B

1

84522361 15/06/2011

A.10.A / 65

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 04 Enhanced high flow option L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

(1) (Pin) (X)

84522361 15/06/2011

A.10.A / 66

High flow pump (2) Flow to EH loader valve - PIN (E) main Reservoir suction line (B)

Hydrostatic pump Charge pump suction line To case drain tube

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

23112911

1

84522361 15/06/2011

A.10.A / 67

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

(1) (2) (A) (C)

84522361 15/06/2011

A.10.A / 68

Right hand motor Left hand motor To case drain tube Crossover pump suction line

(3) (4) (B) (D)

Brake / shift manifold 2 spd Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102459A

1

84522361 15/06/2011

A.10.A / 69

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Single speed drive assembly L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

(1) (2) (A) (C)

84522361 15/06/2011

A.10.A / 70

Right hand motor Left hand motor To case drain tube Crossover pump suction line

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102457A

1

84522361 15/06/2011

A.10.A / 71

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 72

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from charge pump

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102449A

1

84522361 15/06/2011

A.10.A / 73

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed track drive assembly C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

(1) (2) (A) (C) (E)

84522361 15/06/2011

A.10.A / 74

Right hand motor Left hand motor To case drain tube Crossover pump suction line Pilot control pressure from brake / shift / EH valve

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

23112910

1

84522361 15/06/2011

A.10.A / 75

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 76

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from brake / shift / EH valve

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102455 C

1

84522361 15/06/2011

A.10.A / 77

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Enhanced high flow option L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

(1) (Pin) (X)

84522361 15/06/2011

A.10.A / 78

High flow pump (2) Flow to EH loader valve - PIN (E) main Reservoir suction line (B)

Hydrostatic pump Charge pump suction line To case drain tube

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102430B

1

84522361 15/06/2011

A.10.A / 79

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly L223, L225, L230

(1) (2) (A) (C) (E)

84522361 15/06/2011

A.10.A / 80

Right hand motor Left hand motor To case drain tube Crossover pump suction line Pilot control pressure from brake / shift / EH valve

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102462A

1

84522361 15/06/2011

A.10.A / 81

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 82

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from brake / shift / EH valve

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102455 C

1

84522361 15/06/2011

A.10.A / 83

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Enhanced high flow option L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

(1) (Pin) (X)

84522361 15/06/2011

A.10.A / 84

High flow pump (2) Flow to EH loader valve - PIN (E) main Reservoir suction line (B)

Hydrostatic pump Charge pump suction line To case drain tube

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102430B

1

84522361 15/06/2011

A.10.A / 85

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly L218 Electro hydraulic controls, L220 Electro hydraulic controls

(1) (2) (A) (C) (E)

84522361 15/06/2011

A.10.A / 86

Right hand motor Left hand motor To case drain tube Crossover pump suction line Pilot control pressure from brake / shift / EH valve

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102460A

1

84522361 15/06/2011

A.10.A / 87

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Single speed drive assembly L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

(1) (2) (A) (C)

84522361 15/06/2011

A.10.A / 88

Right hand motor Left hand motor To case drain tube Crossover pump suction line

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102458A

1

84522361 15/06/2011

A.10.A / 89

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 90

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from charge pump

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102450A

1

84522361 15/06/2011

A.10.A / 91

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Single speed drive assembly L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls

(1) (2) (A) (C)

84522361 15/06/2011

A.10.A / 92

Right hand motor Left hand motor To case drain tube Crossover pump suction line

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102457A

1

84522361 15/06/2011

A.10.A / 93

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 94

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from charge pump

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102449A

1

84522361 15/06/2011

A.10.A / 95

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Single speed drive assembly L213 Electro hydraulic controls, L215 Electro hydraulic controls

(1) (2) (A) (C)

84522361 15/06/2011

A.10.A / 96

Right hand motor Left hand motor To case drain tube Crossover pump suction line

(3) (4) (B) (D)

Brake / shift manifold Hydrostatic pump Charge pressure to port lock Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102458A

1

84522361 15/06/2011

A.10.A / 97

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly L213 Electro hydraulic controls, L215 Electro hydraulic controls

(1) (2) (3) (4) (5) (6) (7) (8) (9) (A) (C) (E)

84522361 15/06/2011

A.10.A / 98

Left hand hydraulic coupler cylinder Right hand hydraulic coupler cylinder Left hand lift cylinder Right hand lift cylinder Left hand bucket tip cylinder Right hand bucket tip cylinder P/O double check valve Hydraulic coupler valve Ride control Case drain from pumps and motors Crossover pump suction line Pilot control pressure from charge pump

(10)

Self level

(11)

Loader valve

(12) (13) (14) (15) (16) (17) (18) (B)

High flow valve Secondary auxiliary valve Hydraulic oil supply filter Oil cooler Auxiliary pump High flow pump Boom override valve Charge pressure for port lock

(D)

Charge pump suction line

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

231102450A

1

84522361 15/06/2011

A.10.A / 99

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

84522361 15/06/2011

A.10.A / 100

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control valve - Overview Loader bucket control The loader bucket can be dumped and rolled back by the operator with proportional flow control to the bucket tilt cylinders via the dedicated valve section. When shaking the bucket the software will enhance the movement of the bucket. For ISO and H-Pattern, (EH and mechanical hand controls) the loader bucket is dumped by moving the right joystick handle to the right and rolled back by moving the right joystick handle to the left. The further the right joystick is actuated away from the spring centred neutral position, the faster the bucket rolls. For Foot Control, the loader bucket is dumped by pressing the right foot pedal forward and rolled back by pressing the right foot pedal backward. The further the pedal is actuated away from the spring centered neutral position, the faster the bucket rolls. The loader bucket can be controlled only if all of the following conditions are met: Operator Present Operator restraint engaged Door is closed (if equipped) Ignition is on Hydraulics Enabled

84522361 15/06/2011

A.10.A / 102

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Control valve - Overview Loader arm float Float mode is enabled by a fourth position in the loader arm spool which opens a flow-path between both ends of the loader arm cylinders and the tank. This flow path enables the loader arm to be lowered to the ground by relying on gravity rather than on pump flow. Additionally, float allows the loader arm to move freely up and down as it skids across the ground, and thus to “float” over, or follow the contour of the ground while the vehicle is moving. In ISO or H- Pattern (EH only), loader arm float is enabled by depressing and holding the thumb button on the right hand handle while actuating the loader arm control a minimum of half or more in the “lower” direction. Once in float, the switch and handle can be returned to neutral if desired and unit will remain in float. If handle is subsequently moved in the lower direction unit will also remain in float. To cancel float after initiation move the loader control in the “raise” direction. To place the loader arm in float with mechanical hand controls, move the left hand joystick to the right (center of unit) past the detent near the end of travel. Loader arm will remain in float until the joystick is moved to the left (outside) past the detent (into power down range) and returned to neutral. To place the loader arm in float with mechanical foot controls, push forward on the front of the left foot pedal into the detent position near the end of travel. The loader arm will remain in float until the left pedal is pressed on the back of the pedal with enough force to move past the detent (into power down range) and return to neutral.

84522361 15/06/2011

A.10.A / 103

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Cleaning 1.

Prepare the portable filter CAS10162A by doing the following steps: (A) Remove all the hydraulic oil from the inlet and outlet hoses for the portable filter. (B) Remove the filter element from the portable filter. (C) Remove all hydraulic oil from the portable filter. (D) Clean the inside of the housing for the filter element. (E) Install a new filter element in the portable filter.

2.

Determine whether the contamination is microscopic or visible. Refer to: PRIMARY HYDRAULIC POWER SYSTEM - Overview of Contaminates (A.10.A)

3.

If the contamination is microscopic: (A) Check the maintenance schedule for the machine to learn if the hydraulic oil must be changed. If necessary, change the hydraulic oil. Change the hydraulic filter. (B) Do steps 6 through 37.

4.

If the contamination is visible, do the following steps: (A) Change the hydraulic oil and hydraulic filter. (B) Do steps 5 through 37.

5.

Check the amount of contamination in the hydraulic system by doing the following steps: (A) Disassemble one cylinder in two different circuits. Check for damage to seals, scoring of the cylinder wall, etc. Repair the cylinders as necessary. (B) If, in your judgment, the damage to the cylinders was caused by severe contamination and is not the result of normal wear, it is necessary to remove, clean and repair all valves, pumps, lines, cylinders, hydraulic reservoir, etc. in the hydraulic system. To clean the lines refer to the following procedure: TRANSMISSION Hydrostatic - Cleaning (C.20.F)

6.

Remove the cap from the reservoir and install the adapter CAS1871 on the reservoir.

7.

Connect the vacuum pump CAS10192 to the adapter CAS1871. Reservoir - Apply vacuum (A.10.A)

8.

Start the vacuum pump.

9.

The hydraulic reservoir is located at the rear of the machine. Loosen and remove the drain plug from the reservoir.

10.

Using the fitting kit CAS10508, install the valve in the hole for the drain plug. Make sure that the valve is closed.

11.

Stop the vacuum pump.

12.

Connect the inlet hose for the portable filter to the valve that is installed in the hole for the drain plug.

13.

Disconnect the vacuum pump and remove CAS1871 adapter from reservoir.

14.

Install the outlet hose for the portable filter in the hydraulic reservoir filler neck. 84522361 15/06/2011

A.10.A / 104

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

15.

Open the valve that is installed in the hole for the drain plug. (A) Check fluid level in reservoir. Add if necessary.

16.

Move the switch for the portable filter to the ON position.

17.

Start and run the engine at half throttle.

18.

Run the portable filter for 10 minutes with the engine running at half throttle.

19.

Continue to run the portable filter. Increase the engine speed to full throttle. Do the following to heat the oil to operating temperature: (A) Increase the engine speed to full throttle. (B) Hold the bucket control lever in the ROLLBACK position for five seconds. (C) Return the bucket control lever in the NEUTRAL position for five seconds. (D) Repeat steps 19B and 19C until the oil is at operating temperature; 49 - 66 °C (120 - 150 °F).

20.

With the engine running at full throttle and the portable filter running, completely extend and retract the lift cylinders and the bucket cylinders. Continue to operate the cylinders, one after the other for 30 minutes.

NOTE: If the filter light in the machine illuminates, stop the engine, change the filter, then continue with procedure. 21.

Decrease the engine speed to low idle.

22.

Continue to run the portable filter for 10 minutes. During this time, move the hose up and down to help mix the oil in the reservoir.

23.

Stop the portable filter.

24.

Stop the engine.

25.

Remove the hose from the hydraulic reservoir.

26.

Reservoir - Apply vacuum (A.10.A)

27.

Close the valve that is installed in the hole for the drain plug.

28.

Disconnect the inlet hose for the portable filter from the valve.

29.

Start the vacuum pump.

30.

Remove the valve from the hole for the drain plug.

31.

Install and tighten the drain plug.

32.

Stop the vacuum pump.

33.

Disconnect the vacuum pump from the opening in the reservoir.

34.

Install new hydraulic filter elements on the machine.

35.

Start the engine. Check for oil leakage around the new hydraulic filter.

36.

Stop the engine.

37.

Check the level of the oil in the reservoir and add oil as required. Reservoir - Filling (A.10.A)

84522361 15/06/2011

A.10.A / 105

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating WARNING Crushing hazard! If you service the machine with the loader lift arms raised, always use the support strut. Remove the retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support strut. Lower the lift arms onto the support strut. Failure to comply could result in death or serious injury. W0230A

1.

Start and run the engine at 1500 rpm (r/min).

2.

Completely retract all attachment cylinders on the machine. Stop the engine.

3.

Depress the auxiliary hydraulic interlock override button, and leave the seat within 30 s. Move each control lever in both directions to release pressure in the hydraulic circuits.

4.

Loosen and remove the filler cap from the reservoir.

5.

Drain the hydraulic oil from the reservoir. (A) Have available acceptable equipment to drain the hydraulic oil. (B) Remove the drain plug from the bottom of the reservoir.

6.

Remove the hydraulic filter element from the machine.

7.

Install new hydraulic filter element on the machine.

8.

Install the drain plug in the bottom of the reservoir.

9.

Fill the hydraulic reservoir. (A.10.A)

10.

Disconnect the line from the ROD end and BARREL end of each cylinder.

11.

Be sure all control levers are in the NEUTRAL position.

12.

Start and run the engine at low idle.

Reservoir - Filling

NOTICE: Check the oil level in the hydraulic reservoir frequently while doing step 13. Have another person hold a container under the hydraulic lines while you do step 13. 13.

Slowly move the control lever for each bucket and lift cylinders in both directions until oil begins to flow from the open line. Hold the control lever in place until clean oil flows from the open line.

14.

Stop the engine.

15.

Connect the system line to the BARREL end of each cylinder.

16.

Connect a suitable drain line to the ROD end of each cylinder and place the other end in an acceptable container for contaminated oil.

17.

Start the engine and run the engine at low idle.

84522361 15/06/2011

A.10.A / 106

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

18.

Slowly and completely extend all cylinders. As the piston rod comes in/out of the cylinder, oil will be pushed out of the ROD end of the cylinders.

NOTICE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent the attachment from falling. 19.

Support any attachments that will be in the RAISED position.

20.

Stop the engine.

21.

Disconnect the drain lines and connect the system lines to the cylinders.

22.

Check the oil level in the hydraulic reservoir. Add oil as required.

23.

Install the filler cap on the reservoir.

24.

Remove the hydraulic filter element from the machine.

25.

Install a new hydraulic filter element on the machine.

26.

Start and run the engine at 1500 RPM, operate each hydraulic circuit to completely extend and retract the cylinders.

27.

Stop the engine and check for leaks. Check the oil level in the hydraulic reservoir. Add oil as required. Reservoir - Filling (A.10.A)

84522361 15/06/2011

A.10.A / 107

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Relief valve - Flow test Loader main relief valve 1.

Park the machine on a level surface. Lower the loader bucket to the floor. Stop the engine.

2.

Disconnect the hose from the fitting on the pressure port (1) of the hydraulic pump. Install a T fitting at the pressure port (1) on the hydraulic pump. Reconnect the pressure hose to one side of the T fitting. Connect the flowmeter inlet hose to the remaining connection on the T fitting. Place the flowmeter outlet hose into the reservoir. Secure the outlet hose to the reservoir so that the hose is submerged below the surface of the hydraulic oil.

3.

Make sure that the oil level in the hydraulic reservoir is correct.

4.

The oil must be at operating temperature. If the oil is not at operating temperature, run the engine at full throttle. Hold the auxiliary hydraulic flow control pedal in the ON position and close the pressure valve of the flowmeter until the pressure gauge indicates 103 bar (1500 psi). Continue to run the engine at full throttle until the temperature of the oil is 52°C (125°F). Open the pressure valve of the flowmeter fully.

5.

Continue to hold the auxiliary hydraulic flow control pedal in the ON position. Continue to run the engine at full throttle. Slowly close the pressure valve of the flow meter. As the pressure increases, the flow indication will decrease slowly. As you continue to close the pressure valve, you will reach a point at which the flow indication begins to decrease rapidly. This is the point at which the main relief valve starts to open. Read the pressure gauge and record the reading as test number 5.

6.

Continue to close the pressure valve until the indication of the flow gauge is zero. This is the point at which the main relief valve is completely open. Read the pressure gauge and record the reading as test number 6.

7.

Open the pressure valve completely. Decrease the engine speed to low idle and stop the engine.

8.

Refer to specifications Control valve - General specification (A.10.A) Control valve - General specification (A.10.A) If the pressure setting of the main relief valve is not within the specifications, you must replace the main relief valve.

9.

If you replaced the main relief valve, repeat steps 5 through 7.

10.

If the completely open pressure (step 6) is as specified, but the pressure at which the main relief valve begins to open (step 5) is 185 bar (2650 psi) or less, the main relief valve is damaged and must be replaced before you do further testing.

NOTE: Understanding the results of the tests are outlined in the steps below.

84522361 15/06/2011

A.10.A / 108

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

11.

Refer to Hydraulic pump - Flow test (A.10.A) Hydraulic pump - Flow test (A.10.A) If the flow indication for a circuit was approximately the same as the flow indication at the same pressure in Test Number 1 of the Hydraulic Pump Flow Test , the circuit is good.

12.

If the flow indication for a circuit was more than 3.8 L/min (one gpm) less than the flow indication at the same pressure in Hydraulic pump - Flow test (A.10.A) Test Number 1, there is leakage in that circuit.

84522361 15/06/2011

A.10.A / 109

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Relief valve - Pressure test Loader valve main relief CAS1808 NOTE: Flat face couplers are not included with the CAS-1808 Flowmeter Fitting Kit or the CAS-1804 Pressure Test Fitting Kit. 1.

Park the machine on a level surface. Lower the loader bucket to the floor.

2.

The oil must be at operating temperature. To heat the oil, do the following steps: A. With the engine running at full throttle, hold the bucket control lever in the ROLLBACK position for 10 seconds. B. Put the bucket control lever in the NEUTRAL position for 10 seconds. C. Repeat steps A and B until the temperature of the oil is 52° C (125° F) or the side of the reservoir is very warm.

3.

Use a pressure gauge with a capacity of at least 276 bar (4000 psi). Connect the pressure gauge to one of the auxiliary hydraulic couplers on the left hand loader arm.

4.

Run the engine at full throttle. Actuate the auxiliary hydraulic flow control pedal to pressurize the hydraulic line which has the pressure gauge. Record the indication on the pressure gauge. Then return the auxiliary hydraulic flow control pedal to the Neutral position and decrease the engine speed to low idle. Stop the engine.

5.

Compare the indication with the specification. Control valve - General specification (A.10.A) If the indication is not correct, replace the main relief valve. Then do the pressure check again to make sure that the setting is correct.

84522361 15/06/2011

A.10.A / 110

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Flow test Loader hydraulic pump NOTE: Two persons are required to perform the flowmeter tests for safety to avoid possible injury. One person must be seated in the operators seat when the engine is running. The second person is to control the flowmeter and take the readings. 1.

Park the machine on a level surface. Lower the loader bucket to the floor. Stop the engine.

2.

Disconnect the hose from the loader pump pressure port (1) at Test Point 1. Install a plug in the hose. Connect the flowmeter inlet hose to the fitting at the pressure port (1) of the pump. If equipped with high flow, disconnect the hose from the high flow pressure port (2). Install a plug in the hose. Connect a second flowmeter inlet hose to the fitting at the pressure port (2) of the pump.

NOTE: The first picture is for models equipped with a hydraulic gear pump only. The second picture is for models equipped with a hydraulic gear pump with high flow option.

3.

Put the flowmeter outlet hose into the hydraulic reservoir. Use wire to fasten the flowmeter outlet hose below the surface of the hydraulic oil.

4.

Make sure that the oil level in the hydraulic reservoir is correct.

5.

Make sure that the pressure valve of the flowmeter is opened completely.

6.

The oil must be at operating temperature. If the oil is not at operating temperature, run the engine at full throttle and close the pressure valve of the flowmeter until the pressure gauge indicates 103 bar (1500 psi). Continue to run the engine at full throttle until the temperature of the oil is 52°C (125°F). Then open the pressure valve completely.

7.

Make sure that the pressure valves are opened completely. Adjust the engine speed to 2300 r/min (rpm) and read the flow gauge. Read the flow and record the reading as test number 1 .

8.

Slowly close the pressure valve on the flowmeter on the loader pump until the pressure gauge indicates 97 bar (1400 psi). Keep the engine running at 2300 r/min (rpm). Read the flow and record the reading as test number 2 . 84522361 15/06/2011

A.10.A / 111

931002073

1

931001956

2

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

9.

Slowly close the pressure valve on the flowmeter until the pressure gauge indicates 124 bar (1800 psi). Keep the engine running at 2300 r/min (rpm). Read the flow and record the reading as test number 3.

10.

Slowly close the pressure valve on the flowmeter until the pressure gauge indicates 152 bar (2200 psi). Keep the engine running at 2300 r/min (rpm). Read the flow and record the reading as test number 4.

11.

Open the pressure valve completely. If the high flow pump is installed, repeat steps 8 thru 10 on the high flow section. Then decrease the engine speed to low idle and stop the engine.

NOTE: Understanding the results of the tests are outlined in the steps below. 12.

If the output at minimum pressure was less than the specification for Gear Pump Flow to Loader (Machine in Neutral) refer to PRIMARY HYDRAULIC POWER SYSTEM - General specification (A.10.A), the problem can be a restriction between the reservoir and the gear pump, or the problem can be a badly worn or damaged gear pump.

13.

If the output at minimum pressure was more than the specification refer to PRIMARY HYDRAULIC POWER SYSTEM - General specification (A.10.A), there are no problems between the reservoir and the gear pump. However, the gear pump can be worn or damaged and still have good flow at minimum pressure.

14.

Loss of output at 152 bar (2200 psi) indicates that the gear pump is worn or damaged. To determine the efficiency of the gear pump, divide the flow indication from test number 4 by the flow indication from test number 1. This answer multiplied by 100 is the percent efficiency of the gear pump. If the efficiency of the gear pump is less than 70%, repair or replace the gear pump. If the efficiency of the gear pump is more than 70%, the pump is good.

84522361 15/06/2011

A.10.A / 112

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Install NOTE: Before pump installation, apply Molykote G-4700 (P/N 86983138) to the pump and the coupling splines. Pre-fill the pump with clean hydraulic oil. Inspect O-ring on the pump pilot and replace if necessary. Lubricate the O-ring with clean hydraulic oil. 1.

2.

3.

4.

Hold the pump in the mounting location. Rotate the gear pump shaft until it aligns with the coupling (1) splines at the rear of the hydrostatic pump. Shown with call out (X) After the splines are aligned, move the pump inward until the mounting flange is flush with the mounting surface of the hydrostatic pump.

93111555A

1

931001928

2

931001956

3

931001955

4

Apply Loctite 243 to the pump mounting bolts (4). Install washers on the bolts and install the bolts into the pump mounting flange. Tighten the mounting bolts .

Connect gear pump hydraulic hoses (A) and (B), as shown.

Connect the gear pump supply hose (1) and tighten hose clamp.

84522361 15/06/2011

A.10.A / 113

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

5.

6.

7.

8.

Connect case drain hose (2) and secure with clamp.

931001963

5

931001972

6

931001971

7

931001970

8

Connect hydraulic hose (3), as shown.

Connect left hand side drive motor hoses (C) and (D).

Connect right hand side motor hoses (5) and (6).

84522361 15/06/2011

A.10.A / 114

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

9.

Connect the top hydraulic hose (7).

931001966

10.

11.

12.

9

Connect the oil supply hose (8) and tighten hose clamp.

931001965

10

931001964

11

931001963

12

Connect right hand side hydraulic tube (9).

Connect charge pressure switch (10) and secure with nut.

84522361 15/06/2011

A.10.A / 115

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

13.

14.

15.

Connect the right hand side back up alarm connections (11).

931001962

13

931002115

14

931001961

15

Connect the left hand side back up alarm connections (12).

Connect the control wires (E) and (F) located on the bottom of pumps.

84522361 15/06/2011

A.10.A / 116

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Charge pump - Pressure test Testing the low-pressure charge system is safer and usually more informative than going into the high-pressure test ports. To obtain as much system information as possible, charge pressure readings must be taken in neutral as well as working the system in both the forward and reverse directions. With the system in neutral, only charge pressure is present in the closed loop. At this time, the leakage from the system is the least and the charge pressure is the highest. As the system is pressurized, the leakage from the system will increase and the charge pump flow will make up for this leakage. With more of the charge pump oil flowing to the closed loop, less oil will flow across the charge pressure relief valve, and therefore the pressure will be slightly less. If the leakage from the system is excessive, the charge pressure will drop off more. This slight drop in charge pressure between the system in neutral and with the system under load indicates the condition of the closed loop system components. 1.

Raise and securely block the unit off the ground.

2.

Remove the brake release lines from the tee fitting that connects to the B port (1) of the brake valve (2) and cap lines.

931002074

3.

Cap the tee fitting that connects to the B port of the brake valve.

4.

Connect a 4,137 kPa (41 bar) (600 psi) pressure gauge to the charge pressure test port. Remove the hose from the tee fitting and install a 4,137 kPa(600 psi) pressure gauge.

5.

If the hydraulic oil is not at operating temperature, run the engine at full throttle and hold the bucket control lever in the ROLLBACK position for 30 seconds. Then return the bucket control lever to NEUTRAL for 15 seconds. Repeat this cycle until the temperature of the oil is at least 52°C (125°F).

6.

Continue to run the engine at full throttle. Read the pressure gauge and record the Charge Pressure reading. Stop the engine.

7.

The pressure reading must be 25 - 28 bar (362 - 410 psi) or the relief valve must be adjusted with shims.

8.

If the pressure is correct, go to step 10. If the pressure is not correct, loosen the cap on the hydraulic reservoir. Remove the plug, shim(s), spring, and poppet for the charge pressure relief valve.

9.

Inspect the parts of the charge relief valve. If the parts are good, add shim(s) from the shim kit, refer to parts manual, and repeat steps 5 through 9 until the pressure is correct.

NOTICE: For the following test the machine MUST be raised up on supports until the tires are above the floor. This is a safety procedure if the hydraulic parking brakes fail to hold. 84522361 15/06/2011

A.10.A / 117

1

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

10.

After you get the correct charge pressure in NEUTRAL, do the following steps: A. Start and run the engine at low idle. Increase the engine speed to full throttle. If equipped with 2 speed, shift into transport (high) range. Slowly move one of the direction control levers FORWARD to load the hydrostatic piston pump and drive motor without decreasing the engine speed. DO NOT Lug the Engine. Reduced engine speed causes decreased charge pump flow, which will affect the pressure readings. Repeat for the opposite side (only move one lever at a time). B. Read the pressure gauge. The pressure must be within 138 kPa (1.5 bar) (20 psi) of the pressure in step 6. C. Repeat Steps A and B with the direction control levers in REVERSE. Interpretation of the results: Once the charge pressure meets specifications with the levers in the neutral position, compare the pressure readings under load with the neutral readings. The readings should be highest with the levers in the NEUTRAL position, for this is when the direct acting charge relief has to handle the greatest amount of oil flow. The maximum difference in charge pressure readings between the system in neutral and the system loaded in both directions must be not greater than 138 kPa (1.5 bar) (20 psi). Any difference greater than 138 kPa (1.5 bar) (20 psi) indicates excessive leakage from the closed loop, which will require repair.

NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than 138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is damaged in the system, the leakage may only show up under heavy load conditions. NOTE: To determine if the problem is in the pump or the motor do the following: 11.

On the side (left or right) that the charge pressure dropped more than 138kPa (1.5 bar) (20psi), cap the two high-pressure lines that supply the drive motor. The lines can be capped at either the pump or at the motor, which ever is easiest.

NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than 138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is damaged in the system, the leakage may only show up under heavy load conditions. 12.

With the lines capped to the drive motor, start and run the engine at low idle. Increase the engine speed to full throttle. Slowly move the direction control lever that is being tested FORWARD to load the hydrostatic piston pump without decreasing the engine speed. DO NOT Lug the Engine. Reduced engine speed causes decreased charge pump flow, which will affect the pressure readings. 84522361 15/06/2011

A.10.A / 118

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than 138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is damaged in the system, the leakage may only show up under heavy load conditions. 13.

Read the pressure gauge. The pressure must be within 138 kPa (1.5 bar) (20 psi) of the pressure in step 6.

NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than 138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is damaged in the system, the leakage may only show up under heavy load conditions. 14.

Repeat Steps 11 and 12 with the direction control levers in REVERSE. Interpretation of the results with the two high-pressure lines capped to the drive motors: If the charge pressure drops more than 138 kPa (1.5 bar) (20 psi) of the pressure in step 6, the leakage is in the pump. Remember that this is a closed loop hydrostatic system. If one component fails, the debris will be sent directly to the mating component and cause damage. As this damage progresses, contamination will return to the reservoir through the case drain system. At the very least once a failure has occurred, the mating component in the hydrostatic system must be inspected for damage. If any contamination has been returned to the reservoir, tear down and inspection of both complete closed loop systems is necessary since the same charge pump feeds them. Also, because the hydraulic system shares the reservoir with the hydrostatic system, all lines, and components must be thoroughly cleaned to prevent contamination from reentering the repaired system.

NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than 138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is damaged in the system, the leakage may only show up under heavy load conditions.

84522361 15/06/2011

A.10.A / 119

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Charge pump - Pressure test (Machines Equipped with EH Controls) 1.

Connect a 4,137 kPa (41 bar) (600 psi) pressure gauge to test port, (1) see next figure.

NOTICE: For the following test the machine MUST be raised up on supports until the tires are above the floor. This is a safety procedure if the parking brakes fail to hold. NOTE: You will need two people to perform this test. The operator seat must be in the raised position to gain access to the hydrostatic pump.

2.

If the hydraulic oil is not at operating temperature run the engine at full throttle and hold the bucket control lever in the ROLLBACK position for 30 seconds. Then return the bucket control lever to NEUTRAL for 15 seconds. Repeat this cycle until the temperature of the oil is at least 52°C (125°F).

3.

Continue to run the engine at full throttle. Read the pressure gauge and record the Charge Pressure reading. Stop the engine.

4.

The pressure must be a minimum of 2,413 kPa (24 bar) (350 psi) at full throttle.

5.

If the pressure is correct go to step 7. If the pressure is not correct loosen the cap on the hydraulic reservoir. Remove the plug, shim(s), spring, and poppet for the charge relief valve. See figure below.

6.

Inspect the parts of the charge relief valve (1). If the parts are good, add shim(s) from the shim kit and repeat steps 1 through 4 until the pressure is correct.

7.

After you get the correct charge pressure in NEUTRAL, do the following steps.

NOTICE: For the following test the machine MUST be raised up on supports until the tires are above the floor. This is a safety procedure if the parking brakes fail to hold.

84522361 15/06/2011

A.10.A / 120

20111248

1

20111248

2

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

8.

(A.) Start and run the engine at low idle. Engage the parking brake. If equipped with 2 speed, shift into transport (high) range. (B.) Increase the engine speed to full throttle. Slowly move the ground drive control lever FORWARD to load the hydraulic piston pumps without decreasing the engine speed. (C.) Read the pressure gauge. The pressure must be within 138 kPa (1.5 bar) (20 psi) of the pressure in step 3. (D.) Repeat Steps B and C with the ground drive control lever in REVERSE position. Interpretation of the results: Once the charge pressure meets specifications with the levers in the neutral position, compare the pressure readings under load with the neutral readings. The readings should be highest with the levers in the NEUTRAL position, for this is when the direct acting charge relief has to handle the greatest amount of oil flow. The maximum difference in charge pressure readings between the system in neutral and the system loaded in both directions must be not greater than 138 kPa (1.5 bar) (20 psi). Any difference greater than 138 kPa (1.5 bar) (20 psi) indicates excessive leakage from the closed loop, which will require repair.

NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than 138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is damaged in the system, the leakage may only show up under heavy load conditions. NOTE: To determine if the problem is in the pump or the motor do the following: 9.

On the side (left or right) that the charge pressure dropped more than 138kPa (1.5 bar) (20psi), cap the two high-pressure lines that supply the drive motor. The lines can be capped at either the pump or at the motor, which ever is easiest.

NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than 138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is damaged in the system, the leakage may only show up under heavy load conditions. 10.

With the lines capped to the drive motor, start and run the engine at low idle. Increase the engine speed to full throttle. Slowly move the direction control lever that is being tested FORWARD to load the hydrostatic piston pump without decreasing the engine speed. DO NOT Lug the Engine. Reduced engine speed causes decreased charge pump flow, which will affect the pressure readings.

NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than 138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is damaged in the system, the leakage may only show up under heavy load conditions.

84522361 15/06/2011

A.10.A / 121

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

11.

Read the pressure gauge. The pressure must be within 138 kPa (1.5 bar) (20 psi) of the pressure in step 3.

NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than 138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is damaged in the system, the leakage may only show up under heavy load conditions. 12.

Repeat Steps 9 and 10 with the direction control levers in REVERSE. Interpretation of the results with the two high-pressure lines capped to the drive motors: If the charge pressure drops more than 138 kPa (1.5 bar) (20 psi) of the pressure in step 3, the leakage is in the pump. Remember that this is a closed loop hydrostatic system. If one component fails, the debris will be sent directly to the mating component and cause damage. As this damage progresses, contamination will return to the reservoir through the case drain system. At the very least once a failure has occurred, the mating component in the hydrostatic system must be inspected for damage. If any contamination has been returned to the reservoir, tear down and inspection of both complete closed loop systems is necessary since the same charge pump feeds them. Also, because the hydraulic system shares the reservoir with the hydrostatic system, all lines, and components must be thoroughly cleaned to prevent contamination from reentering the repaired system.

NOTE: The charge pressure drop indicates internal leakage from the system with the system under load. This is caused by less oil flowing over the charge relief and therefore, the lower pressure. Excessive leakage (greater than 138 kPa (1.5 bar) (20 psi) will result in slower drive speed on that side of the machine, but depending on what is damaged in the system, the leakage may only show up under heavy load conditions.

84522361 15/06/2011

A.10.A / 122

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Reservoir - Apply vacuum 1.

Remove the cap from the hydraulic reservoir.

2.

Install an adapter cap CAS1871 on the filler neck.

3.

Connect the vacuum pump CAS10193 to the adapter.

4.

Start the vacuum pump.

84522361 15/06/2011

A.10.A / 123

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Reservoir - Filling 1.

Lower the loader lift arms to the ground and shut off the engine.

2.

Clean the reservoir filler cap and the area around the filler cap with cleaning solvent.

3.

Turn the filler cap 1/2 turn to relieve air pressure from the reservoir. Do not remove the filler cap from the reservoir until the pressure is relieved.

4.

Remove the filler cap from the reservoir.

5.

Add the correct oil, CNH MAT3509, to the reservoir until the proper oil level in the reservoir is established. Fill the reservoir until the oil level is at the midpoint of the sight gauge. Install the reservoir cap.

6.

Start and run the engine and operate the hydraulics. Lower the loader lift arms to the ground. Stop the engine and check the oil level in the reservoir. Add oil as required.

84522361 15/06/2011

A.10.A / 124

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Reservoir - Visual inspection 1.

Check the reservoir for wear, cracks, and leaks. Repair as required.

NOTICE: Do not modify the strainer, as any material that gets past the strainer can go directly to the gear pump, control valve, cylinders, and auxiliary hydraulic attachment and cause major damage to these components. 2.

Inspect the strainer. Remove and replace if the strainer is dirty or clogged.

3.

Inspect the return line port, and suction line port, for cracks and debris buildup. Repair as required.

84522361 15/06/2011

A.10.A / 125

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Filter - Remove Prior operation: Reservoir - Apply vacuum (A.10.A). 1.

The filter base can be removed by opening the rear door and lifting the rear engine hood. Loosen and remove the filter element (1) from the filter base.

2.

Remove the ground wire (2).

3.

Remove the inlet, (3), and outlet, (4), oil lines and cap to prevent loss of oil.

4.

Stop vacuum pump.

5.

Loosen and remove the filter base mounting bolts (5).

6.

Remove the filter base assembly from the unit.

84522361 15/06/2011

A.10.A / 126

93107491

1

93106865

2

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Filter - Install Prior operation: Reservoir - Apply vacuum (A.10.A). 1.

2.

Reinstall the filter base with the hardware previously removed (1). Torque the mounting hardware to 20 Nm ( 15 lb ft).

1

93107491

2

93106865

3

Reinstall the hydraulic lines (2) and (3) and tighten the lines to seat line on fittings; loosen and re-torque.

3.

Stop vacuum pump.

4.

Connect the ground wire (4) to the filter sensor.

5.

93106865

Coat the seal ring on a new filter element with clean 10W-30 oil, and tighten the new filter element hand tight 23.0 - 17.6 N·m (17 - 13 lb ft) .

84522361 15/06/2011

A.10.A / 127

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Oil cooler - Remove for models equipped with ISM engine L213, L215, L218, L220

Prior operation: Radiator - Remove (B.50.A). 1.

2.

3.

Drain hydraulic oil reservoir by removing drain plug (1).

931001657

1

931001660

2

931001661

3

If required, remove fan shroud mounting hardware (1).

Remove engine oil dip stick mounting bolt (1).

84522361 15/06/2011

A.10.A / 128

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

4.

5.

6.

7.

Remove coolant overflow hose (1) and tank bracket (2).

931001662

4

931002064

5

931001666

6

931001665

7

Remove fan shroud (1).

Label and disconnect cooler hydraulic lines (1) and cap open ports.

Remove oil cooler mounting hardware (1) from both left and right hand sides.

84522361 15/06/2011

A.10.A / 129

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

8.

Remove oil cooler (1) from the machine.

931001667

Next operation: Oil cooler - Install for machines equipped with ISM engine (A.10.A)

84522361 15/06/2011

A.10.A / 130

8

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Oil cooler - Install for machines equipped with ISM engine L213, L215, L218, L220

Prior operation: Oil cooler - Remove for models equipped with ISM engine (A.10.A) 1.

2.

3.

Position oil cooler (1) in proper mounting location.

931001667

1

931001665

2

931001666

3

Install oil cooler mounting hardware (1) on both left and right hand sides. Tighten hardware to standard torque.

Connect oil cooler hydraulic lines (1) to correct ports. Tighten fittings to standard torque.

84522361 15/06/2011

A.10.A / 131

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

4.

5.

6.

7.

Install fan shroud (1) and center on fan for consistent gap of 9 mm (0.4 in) around entire circumference.

931002064

4

931001662

5

931001661

6

931001660

7

Install coolant over flow hose and wire ties (1). Install bracket mounting bolt (2).

Install engine oil dip stick mounting bolt (1).

Install fan shroud and secure with mounting hardware (1).

NOTE: Center shroud on fan for consistent gap (9mm minimum clearance) around entire circumference.

84522361 15/06/2011

A.10.A / 132

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

8.

Install drain plug (1) in hydraulic reservoir.

931001657

Next operation: Radiator - Install (B.50.A) and Reservoir - Filling (A.10.A)

84522361 15/06/2011

A.10.A / 133

8

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Oil cooler - Remove - for machines equipped with F5C engine L223, L225, L230, C227, C232, C238

Prior operation: Radiator - Remove (B.50.A) 1.

2.

3.

Drain hydraulic oil reservoir by removing drain plug (1).

931001657

1

931001874

2

931001872

3

Remove coolant overflow tank by removing mounting bolt (1).

Remove engine oil dip stick mounting bolt (1).

84522361 15/06/2011

A.10.A / 134

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

4.

5.

6.

7.

Remove the four mounting bolts (1) and pull fan away from hub.

931001879

4

931001877

5

931001881

6

931001882

7

Remove fan shroud mounting hardware (1) then remove fan shroud.

Label and disconnect oil cooler hydraulic lines (1) and cap open ports.

Remove oil cooler mounting hardware (1).

84522361 15/06/2011

A.10.A / 135

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

8.

Remove oil cooler (1).

931001884

Next operation: Oil cooler - Install (A.10.A)

84522361 15/06/2011

A.10.A / 136

8

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Oil cooler - Install - for machines equipped with F5C engine L223, L225, L230, C227, C232, C238

1.

2.

3.

4.

Place oil cooler (1) in proper mounting location.

931001884

1

931001882

2

931001881

3

931001877

4

Install oil cooler mounting hardware (1).

Connect oil cooler hydraulic lines (1) to correct ports.

Install fan shroud using mounting hardware (1).

84522361 15/06/2011

A.10.A / 137

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

5.

Install fan on hub and secure using four mounting bolts (1).

6.

Adjust shroud to have a consistent gap 9 mm (0.4 in) around the entire circumference of the fan/shroud interface.

7.

8.

9.

931001879

5

931001872

6

931001874

7

931001657

8

Install engine oil dip stick mount using mounting bolt (1).

Install coolant overflow hose (1), and tank bracket securing with mounting bolt (2).

Install drain plug (1) in reservoir.

10.

Radiator - Install (B.50.A).

11.

Fill hydraulic oil reservoir refer to Reservoir - Filling (A.10.A). 84522361 15/06/2011

A.10.A / 138

Index HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A PRIMARY HYDRAULIC POWER SYSTEM - 10.A PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Single speed drive assembly . . . . . 62 L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly . . . . . . . . . . . . . . . . 64 L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 04 Enhanced high flow option . . . . . . . 66 L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly . . . . . . . 68 L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Single speed drive assembly . . . . . 70 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly . . . . . . . . . . . . . . . . 72 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed track drive assembly . . 74 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly . . . . . . . . . . . . . . . . 76 L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Enhanced high flow option . . . . . . . 78 L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly . . . . . . . 80 L223, L225, L230

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly . . . . . . . . . . . . . . . . 82 L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Enhanced high flow option . . . . . . . 84 L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly . . . . . . . 86 L218 Electro hydraulic controls, L220 Electro hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Single speed drive assembly . . . . . 88 L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 03 Valve assembly . . . . . . . . . . . . . . . . 90 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Single speed drive assembly . . . . . 92 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly . . . . . . . . . . . . . . . . 94 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Single speed drive assembly . . . . . 96 L213 Electro hydraulic controls, L215 Electro hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 02 Valve assembly . . . . . . . . . . . . . . . . 98 L213 Electro hydraulic controls, L215 Electro hydraulic controls

Charge pump - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Charge pump - Pressure test (Machines Equipped with EH Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Control valve - General specification High Flow Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Control valve - General specification Mechanical Hand Control Loader valve on all models . . . . . . . . . . . . . . . . . 17 L213, L215, L218, L220

Control valve - General specification of Mechanical Foot Control Loader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Control valve - General specification of Secondary Auxiliary Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Control valve - General specification of the EH Control Loader Valve for all models . . . . . . . . . . . . . . . . . . . . . . . . 16 84522361 15/06/2011

A.10.A / 139

Control valve - General specification of the EH and Mechanical boom override valve on all models . . . . . . . . . . 19 Control valve - General specification of the Ride Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Control valve - Overview Loader Lift Control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Control valve - Overview Loader arm float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Control valve - Overview Loader bucket control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Filter - General specification Hydraulic oil return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Filter - General specification Hydraulic oil supply strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Hydraulic pump - Flow test Loader hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Hydraulic pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Oil cooler - Install - for machines equipped with F5C engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 L223, L225, L230, C227, C232, C238

Oil cooler - Install for machines equipped with ISM engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 L213, L215, L218, L220

Oil cooler - Remove - for machines equipped with F5C engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 L223, L225, L230, C227, C232, C238

Oil cooler - Remove for models equipped with ISM engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 L213, L215, L218, L220

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of cylinders on large frame models . . . . 53 L223, L225, L230, C232, C238

PRIMARY HYDRAULIC POWER SYSTEM - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 PRIMARY HYDRAULIC POWER SYSTEM - Component identification of cylinders on medium frames . . . . . . . 49 L218, L220, C227

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of cylinders on small frame models . . . . 48 L213, L215

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of hydraulic motors . . . . . . . . . . . . . . . . . . 55 L223, L225, L230, C232, C238

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of hydraulic motors . . . . . . . . . . . . . . . . . . 56 L218, L220

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of hydraulic motors on small frame models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 L213, L215

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of hydraulic valves . . . . . . . . . . . . . . . . . . 37 L213, L215

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of hydraulic valves . . . . . . . . . . . . . . . . . . 23 L223, L225, L230, C232, C238

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of hydraulic valves . . . . . . . . . . . . . . . . . . 28 L218, L220, C227

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of pumps of large frame models . . . . . . 40 L223, L225, L230, C232, C238

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of pumps on medium frame models . . . 44 L218, L220, C227

PRIMARY HYDRAULIC POWER SYSTEM - Component identification of pumps on small frame models . . . . . . 47 L213, L215

PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 PRIMARY HYDRAULIC POWER SYSTEM - General specification for 34.1cc Front pump with rear pump 23.0cc 10 L230

PRIMARY HYDRAULIC POWER SYSTEM - General specification for the 24.9cc Gear Pump . . . . . . . . . . . . . . . . 6 L218, L220

PRIMARY HYDRAULIC POWER SYSTEM - General specification for the 34.1cc Gear pump with high flow 12.5cc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C227

PRIMARY HYDRAULIC POWER SYSTEM - General specification for the 34.1cc Gear pump with high flow 18.3cc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 L223, L225, L230, C232, C238

PRIMARY HYDRAULIC POWER SYSTEM - General specification of the 20.4cc gear pump . . . . . . . . . . . . . . . . . 9 L213, L215

PRIMARY HYDRAULIC POWER SYSTEM - General specification of the 24.9cc Gear pump with high flow 12.5cc pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L218, L220

PRIMARY HYDRAULIC POWER SYSTEM - General specification of the 34.1cc gear pump . . . . . . . . . . . . . . . . . 8 L223, L225, L230, C227, C232, C238

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schematic frame 01 Two speed drive assembly . . . . . . . 60 L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls

84522361 15/06/2011

A.10.A / 140

PRIMARY HYDRAULIC POWER SYSTEM - Overview EH Drive Pattern Selector Switch . . . . . . . . . . . . . . . . . . . 22 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

PRIMARY HYDRAULIC POWER SYSTEM - Overview of Contaminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Relief valve - Flow test Loader main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Relief valve - Pressure test Loader valve main relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Reservoir - Apply vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Reservoir - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Reservoir - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

84522361 15/06/2011

A.10.A / 141

84522361 15/06/2011

A.10.A / 142

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A SECONDARY HYDRAULIC POWER SYSTEM - 12.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

A.12.A / 1

Contents HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A SECONDARY HYDRAULIC POWER SYSTEM - 12.A

SERVICE SECONDARY HYDRAULIC POWER SYSTEM Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

A.12.A / 2

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - SECONDARY HYDRAULIC POWER SYSTEM

SECONDARY HYDRAULIC POWER SYSTEM - Flow test NOTE: Both of the loader control valve spools must be in the NEUTRAL position during the following test. NOTE: If the auxiliary hydraulic circuit is connected to an attachment using a hydraulic motor, this flow test does not apply. 1.

Push down one side of the auxiliary hydraulic flow control switch and adjust the pressure valve on the flow meter until the pressure gauge indicates 124 bar (1800 psi). Adjust the engine speed to keep the engine running at 2300 r/min (rpm). Read the flow gauge and record the reading as test number 11.

2.

Push down the opposite side of the auxiliary hydraulic flow control switch and adjust the pressure valve on the flow meter until the pressure gauge indicates 124 bar (1800 psi). Adjust the engine speed to keep the engine running at 2300 r/min (rpm). Read the flow gauge and record the reading as test number 12.

3.

Open the pressure valve completely. Decrease the engine speed to low idle and stop the engine.

NOTE: Understanding the results of the tests are outlined in the steps below. 4.

Refer to Hydraulic pump - Flow test (A.10.A) If the flow indication for a circuit was approximately the same as the flow indication at the same pressure in Test Number 1 of the Hydraulic Pump Flow Test , the circuit is good.

5.

If the flow indication for a circuit was more than 3.8 L/min (one gpm) less than the flow indication at the same pressure in Hydraulic pump - Flow test (A.10.A) Test Number 1, there is leakage in that circuit.

6.

Leakage in the auxiliary circuits can be caused by any of the following problems: A. Inadequate control spool travel. B. Damaged or worn packing in one or both of the cylinders. C. Damaged or worn spool or spool bore in the loader control valve.

7.

If the flow indication for every circuit tested was more than 3.8 L/min (one gpm) less than the flow indication at the same pressure in Hydraulic pump - Flow test (A.10.A) test number. 1, there is leakage at a point common to the entire system. A probable cause is a damaged or worn main relief valve or seals.

84522361 15/06/2011

A.12.A / 3

Index HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A SECONDARY HYDRAULIC POWER SYSTEM - 12.A SECONDARY HYDRAULIC POWER SYSTEM - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

A.12.A / 4

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A HYDRAULIC COMMAND SYSTEM - 14.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

A.14.A / 1

Contents HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A HYDRAULIC COMMAND SYSTEM - 14.A

FUNCTIONAL DATA Command Overview Hydraulic Enable Switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

A.14.A / 2

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - HYDRAULIC COMMAND SYSTEM

Command - Overview Hydraulic Enable Switch - Overview The hydraulics enable switch is a safety mechanism that allows the operator to turn on and off all hydraulic functions on the machine. This switch allows an element of safety to allow operator to disable hydraulics when around people and when he wants to deactivate the joystick controls to avoid unintended operation. The switch will activate and deactivate all loader and ground drive functions. The hydraulics enable switch is located in the instrument cluster. This button must be pressed once to enable hydraulics and turn off park brake. It must be pressed and released within 10 seconds. Every subsequent time the button is pressed the loader and ground drive hydraulics will be cycled off and on. If the switch is unable to engage due to the conditions below not being met, an audible alarm will alert the operator. The backlight of the hydraulics enable switch will flash when the engine is on and hydraulics are disabled, indicating to the operator that he must press the hydraulics enable button to begin using the machine. The hydraulics enable switch can only enable the hydraulics while all of the following conditions are met: Operator is seated properly Operator Restraint engaged The ignition is on Proportional joystick control controls must be centered in their neutral positions Crank is not being commanded Valve Logic Port Lock Park Brake Drive Interlock Loader Interlock

Enabled Open Deactivated Unlocked Unlocked

Disabled Closed Engaged Locked Locked

When hydraulics are disabled and re-enabled, the park brake is overridden. If the park brake is applied and the operator disables hydraulics, then re-enables hydraulics, the park brake will then be released. When aux thumbwheel is in the detented position during Hydraulic enable, the software will keep the aux control disabled until the aux thumbwheel has returned to the neutral position. Hydraulics can be disabled any time regardless if joysticks are in neutral.

84522361 15/06/2011

A.14.A / 3

Index HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A HYDRAULIC COMMAND SYSTEM - 14.A Command - Overview Hydraulic Enable Switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

A.14.A / 4

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A HIGH-FLOW HYDRAULIC POWER SYSTEM - 16.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

A.16.A / 1

Contents HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A HIGH-FLOW HYDRAULIC POWER SYSTEM - 16.A

SERVICE Control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L218, L220, L223, L225, L230, C227, C232, C238

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84522361 15/06/2011

A.16.A / 2

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - HIGH-FLOW HYDRAULIC POWER SYSTEM

Control valve - Remove L218, L220, L223, L225, L230, C227, C232, C238

Prior operation: Tilt system - Tilt (E.34.A). 1.

2.

Locate valve (1) on floor of the skid loader under hydraulic pump.

931001948

1

931001689

2

931001689

3

Disconnect the left hydraulic tube (2).

NOTE: Arrow indicates forward direction.

3.

Disconnect hydraulic tubes (3) and (4) from the right of the valve.

NOTE: Arrow indicates forward direction.

84522361 15/06/2011

A.16.A / 3

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - HIGH-FLOW HYDRAULIC POWER SYSTEM 4.

5.

6.

Disconnect the valves electrical connection (5).

931001689

4

931001689

5

931001690

6

Remove the two mounting bolts (2).

Remove valve.

84522361 15/06/2011

A.16.A / 4

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - HIGH-FLOW HYDRAULIC POWER SYSTEM

Control valve - Install 1.

2.

Locate the proper location on the floor for installation of valve.

931001948

1

931001689

2

931001689

3

931001689

4

Install the two mounting bolts (1) through the valve and secure it to the floor.

NOTE: Arrow indicates forward direction.

3.

Connect the two hydraulic tubes (2) and (3) to the right side of the valve.

NOTE: Arrow indicates forward direction.

4.

Connect the top hydraulic tube (4).

NOTE: Arrow indicates forward direction.

84522361 15/06/2011

A.16.A / 5

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - HIGH-FLOW HYDRAULIC POWER SYSTEM 5.

Connect electrical connection (5).

NOTE: Arrow indicates forward direction.

931001689

6.

Lower cab refer to Tilt system - Lower (E.34.A).

84522361 15/06/2011

A.16.A / 6

5

Index HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A HIGH-FLOW HYDRAULIC POWER SYSTEM - 16.A Control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L218, L220, L223, L225, L230, C227, C232, C238

84522361 15/06/2011

A.16.A / 7

84522361 15/06/2011

A.16.A / 8

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A ELECTRICAL POWER SYSTEM - 30.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

A.30.A / 1

Contents HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A ELECTRICAL POWER SYSTEM - 30.A

TECHNICAL DATA Fuse and relay box General specification Main Power Distribution Fuse Block 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General specification Accessory Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Sensing system General specification Resistance to Temperature Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUNCTIONAL DATA ELECTRICAL POWER SYSTEM Component identification Relay Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Component identification Sensor Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Component identification Motor Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Component identification Solenoid Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ELECTRICAL POWER SYSTEM - Component identification Diode Index . . . . . . . . . . . . . . . . . . . . . . . . . 22 Component identification Lighting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Component identification Miscellaneous Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Component identification Switch Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Overview Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Overview Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Overview Resistance devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Overview Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Overview Pulse width modulation (PWM) solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Component identification Fuse Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Component identification Fuse Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Fuse and relay box Relay - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Fuse - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Overview Location and access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 84522361 15/06/2011

A.30.A / 2

Connector Component diagram 01 - Connector X-10 to Connector X-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Component diagram 02 - Connector X-14 to Connector X-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Component diagram 03 - Connector X-161 to Connector X-194 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Component diagram 04 - Connector X-195 to Connector X-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Component diagram 05 - Connector X-22 to Connector X-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Component diagram 06 - Connector X-233 to Connector X-275 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Component diagram 07 - Connector X-28 to Connector X-303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Component diagram 08 - Connector X-304 to Connector X-317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Component diagram 09 - Connector X-318 to Connector X-332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Component diagram 10 - Connector X-333 to Connector X-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Component diagram 11 - Connector X-365 to Connector X-406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Component diagram 12 - Connector X-407 to Connector X-430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Component diagram 13 - Connector X-432 to Connector X-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Component diagram 14 - Connector X-502A to Connector X-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Component diagram 15 - Connector X-512 to Connector X-52A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Component diagram 16 - Connector X-52B to Connector X-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Component diagram 17 - Connector X-75 to Connector X-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Component diagram 18 - Connector X-93 to Connector X-AC_COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Component diagram 19 - Connector X-ACC to Connector X-C01A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Component diagram 20 - Connector X-C01B to Connector X-CAB_GNDB . . . . . . . . . . . . . . . . . . . . . . . 121 Component diagram 21 - Connector X-CC1A to Connector X-CHS_GND_RR . . . . . . . . . . . . . . . . . . . . 126 Component diagram 22 - Connector X-CN1A to Connector X-CN4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Component diagram 23 - Connector X-CN4B to Connector X-ECC2A . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Component diagram 24 - Connector X-ECC2B to Connector X-ECC6B . . . . . . . . . . . . . . . . . . . . . . . . . . 144 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Component diagram 25 - Connector X-EGR to Connector X-FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Component diagram 26 - Connector X-FUSE1 to Connector X-HORN-GND . . . . . . . . . . . . . . . . . . . . . 153 Component diagram 27 - Connector X-HORN-PWR to Connector X-K-C4 . . . . . . . . . . . . . . . . . . . . . . . 157 Component diagram 28 - Connector X-NEG_TERM_A to Connector X-POS_TERM_A . . . . . . . . . . . . 159 Component diagram 29 - Connector X-POS_TERM_B to Connector X-UJMR . . . . . . . . . . . . . . . . . . . . 164 Component identification Engine connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 L223, L225, L230, C227, C232, C238

Component diagram 99 Engine connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 L223, L225, L230, C227, C232, C238

Wiring harness Electrical schematic frame 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Electrical schematic frame 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Electrical schematic frame 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Electrical schematic frame 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Electrical schematic frame 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

84522361 15/06/2011

A.30.A / 3

Electrical schematic frame 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Electrical schematic frame 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Electrical schematic frame 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Electrical schematic frame 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 Electrical schematic frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 Electrical schematic frame 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Electrical schematic frame 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 L223, L225, L230, C227, C232, C238

Electrical schematic frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 L213, L215, L218, L220

Electrical schematic frame 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Electrical schematic frame 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 Electrical schematic frame 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 L213 WE, L215 WE, L218 WE, L220 WE, L223 WE, L225 WE, L230 WE, C227 WE, C232 WE, C238 WE

Electrical schematic frame 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Electrical schematic frame 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Electrical schematic frame 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Electrical schematic frame 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 Electrical schematic frame 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Electrical schematic frame 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 L223, L225, L230, C227, C232, C238

Electrical schematic frame 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 Electrical schematic frame 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 Electrical schematic frame 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Electrical schematic frame 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Electrical schematic frame 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Electrical schematic frame 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electrical schematic frame 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electrical schematic frame 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electrical schematic frame 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electrical schematic frame 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electrical schematic frame 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electrical schematic frame 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 L223, L225, L230, C227, C232, C238

Detailed view Harness Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 84522361 15/06/2011

A.30.A / 4

Sensing system Overview Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Overview Speed and position sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

SERVICE ELECTRICAL POWER SYSTEM Electrical test Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 Electrical test Short to Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 Electrical test Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Battery Check Maintenance Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

Wiring harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

DIAGNOSTIC ELECTRICAL POWER SYSTEM Testing Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 Testing General Wire Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

Fuse and relay box Testing Accessory Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 Testing Condenser Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 Testing Crank Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Testing Engine Preheat Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 Testing Front Electric Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 Testing Lights Relay #1 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Testing Lights Relay #2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 Testing Main Power Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 Testing Option Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 Testing UCM Power Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Auxiliary power connection Testing Electric Auxiliary Hydraulic On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

84522361 15/06/2011

A.30.A / 5

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - General specification Main Power Distribution Fuse Block 1 NOTE: For more information on specific relays see ELECTRICAL POWER SYSTEM - Component identification Relay Index (A.30.A). NOTE: For more information on specific fuses see ELECTRICAL POWER SYSTEM - Component identification Fuse Index (A.30.A). NOTE: For access to fuse blocks see Fuse and relay box - Overview Location and access (A.30.A). See schematic Wiring harness - Electrical schematic frame 04 (A.30.A). MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 Component Name CRANK RELAY MAIN POWER RELAY LIGHTS RELAY #1 LIGHTS RELAY #2 ACCESSORY RELAY HVAC FUSE COMPRESSOR FUSE CRANK FUSE REAR WORK LAMPS FUSE (EH) SIDE LAMPS FUSE (Mech) SIDE LAMPS FUSE (EH) LH TAIL LAMP FUSE (Mech) LH TAIL LAMP FUSE (EH) RH TAIL LAMP FUSE (Mech) UCM BACKUP ALARM FUSE (EH) INSTRUMENT CLUSTER FUSE (Mech) INSTRUMENT CLUSTER FUSE (EH) IGNITION FUSE (Mech) IGNITION FUSE (EH) ACC / BEACON FUSE (Mech) RH TAIL LAMP FUSE (EH) ACCESSORY FUSE (Mech) UNSWITCHED BATTERY FUSE FRONT WORK LAMPS FUSE (EH) REAR WORK LAMPS FUSE (Mech) ACCESSORY FUSE (EH) FRONT WORK LAMPS FUSE (Mech) ACC / BEACON FUSE (EH) WIPER WASHER FUSE (Mech)

Component ID K-007 K-009 K-001 K-002 K-018 F-001 F-002 F-003 F-004 F-004 F-005 F-005 F-006 F-006 F-007 F-007 F-008 F-008 F-009 F-009 F-010 F-010 F-011 F-012 F-012 F-013 F-013 F-014 F-014

84522361 15/06/2011

A.30.A / 6

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - General specification Accessory Power Distribution NOTE: For more information on specific relays see ELECTRICAL POWER SYSTEM - Component identification Relay Index (A.30.A). NOTE: For more information on specific fuses see ELECTRICAL POWER SYSTEM - Component identification Fuse Index (A.30.A). NOTE: For access to fuse blocks see Fuse and relay box - Overview Location and access (A.30.A). See schematic Wiring harness - Electrical schematic frame 05 (A.30.A). ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 Z-FUSE2 (EH) Component Name FRONT ELECTRIC RELAY OPTION RELAY UCM POWER RELAY UCM BRAKE LAMPS FUSE UCM GRND DRV INTERLOCKS FUSE UCM PUMP REV FUSE UCM PROP AUX FUSE UCM BUCKET FUSE HIGH FLOW / COUPLER FUSE UCM PUMP FWD FUSE UCM BOOM FUSE FE HOT FUSE FE #1, #2, #3 FUSE UCM INTERLOCKS FUSE UCM UNSWITCHED BATTERY FUSE UCM 2SPD FUSE FE ON / OFF FUSE WIPER / WASHER FUSE FLASHER / BRAKE FUSE LH BOOM FUSE RH BOOM FUSE

Component ID K-017 K-019 K-003 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

ACCESSORY POWER DISTRIBUTION Z-FUSE2 (Mech) Component Name FRONT ELECTRIC RELAY OPTION RELAY FE HOT FUSE FE #1, #2, #3 FUSE HIGH FLOW / COUPLER FUSE FE ON / OFF FUSE FLASHER / BRAKE FUSE LH BOOM FUSE RH BOOM FUSE

Component ID K-017 K-019 F-015 F-016 F-017 F-018 F-019 F-020 F-021

84522361 15/06/2011

A.30.A / 7

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Sensing system - General specification Resistance to Temperature Conversion Chart Resistance to Temperature Conversion for Hydraulic Oil Temperature and Engine Coolant Temperature Sensors Resistance (in Ω) > 128318 128318 88806.4 63399.2 44472.7 32123.4 23479.7 17393.7 13020.7 9851.1 7528.2 5807.9 4521.3 3550 2810 2241.5

Temperature (in °C) -40 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30

Resistance (in Ω) 1801.2 1457.5 1187.3 973.3 802.8 665.9 465.8 392.6 332.5 79.2 70 62 55.1 49.1 < 49.1

Hydraulic Oil Temperature Bar Conversion Temperature (in °C) < 21 21 37 60 82 90 98 104 110 > 110

Bars 1 1 2 3 4 5 6 7 8 8

Engine Coolant Temperature Bar Conversion Temperature (in °C) < 21 21 37 60 82 98 101 104 108 > 108

Bars 1 1 2 3 4 5 6 7 8 8

84522361 15/06/2011

A.30.A / 8

Temperature (in °C) 35 40 45 50 55 60 70 75 80 130 135 140 145 150 150

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Component identification Relay Index NOTE: For General Relay information see Fuse and relay box Relay - Overview (A.30.A) and Fuse and relay box - Testing Relay Testing (A.50.A). NOTE: For access to fuse blocks see Fuse and relay box - Overview Location and access (A.30.A). NOTE: All relays except Engine Preheat and Flasher, are the same, and may be interchanged for easier troubleshooting. Frame Location Component CompoName nent ID Accessory Relay K-018 Wiring harness - Electrical schematic frame 04 (A.30.A)

Connector Located in MAIN POWER DISTRIBUTION FUSE BLOCK 1

Condenser Relay

K-020 (EH) K-003 (Mech)

Wiring harness - Electrical schematic frame 17 (A.30.A)

X-111

Crank Relay

K-007

Wiring harness - Electrical schematic frame 04 (A.30.A)

Located in MAIN POWER DISTRIBUTION FUSE BLOCK 1

Engine Preheat Relay

K-004

Wiring harness - Electrical schematic frame 11 (A.30.A)

X-PRHT

Front Electric Relay

K-017

Wiring harness - Electrical schematic frame 05 (A.30.A)

Located in ACCESSORY POWER DISTRIBUTION

Lights Relay #1

K-001

Lights Relay #2

K-002

Wiring harness - Electrical schematic frame 04 (A.30.A) Wiring harness - Electrical schematic frame 04 (A.30.A)

Located in MAIN POWER DISTRIBUTION FUSE BLOCK 1 Located in MAIN POWER DISTRIBUTION FUSE BLOCK 1

84522361 15/06/2011

A.30.A / 9

Supplies Power to Radio HVAC box Seat Heat switch Self Level switch Door Wiper motor Wiper / Washer switch Rear Wiper motor Lamp Selector switch Alternator Dome Light HVAC Condenser fan

Diagnostic Fuse and relay box - Testing Accessory Relay Control (A.30.A)

Fuse and relay box - Testing Condenser Relay Control (A.30.A) Starter 3403 - Starter - Starter is cranked > 30s Fuse and relay box - Testing Crank Relay Control (A.30.A) 3156 - Engine Glow Plugs Preheat - Glow Plug - OC Fuse and relay box - Testing Engine Preheat Relay Control (A.30.A) Multifunction Attachment Fuse and relay box - Testing connector Left Hand Control Handle Front Electric Right Hand Control Handle Relay Control Electric Auxiliary Hydraulic (A.30.A) on/off switch Fuse and relay Tail lights box - Testing Work lights Lights Relay #1 Side lights Control (A.30.A) Rear Work lights Fuse and relay box - Testing Lights Relay #2 Control (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name Main Power Relay

Frame Location Component ID K-009 Wiring harness - Electrical schematic frame 04 (A.30.A)

Option Relay

K-019

UCM Power Relay (EH)

K-003 (EH)

Flasher Module (EU)

Z-013 (EU)

Connector Located in MAIN POWER DISTRIBUTION FUSE BLOCK 1

Wiring harness - Electrical schematic frame 05 (A.30.A) Wiring harness - Electrical schematic frame 05 (A.30.A) (EH)

Located in ACCESSORY POWER DISTRIBUTION Located in ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 Z-FUSE2 (EH)

Wiring harness - Electrical schematic frame 16 (A.30.A) (EU)

X-411 (EU)

84522361 15/06/2011

A.30.A / 10

Supplies Power to

Diagnostic

Telematics Instrument Cluster EGR (F5C) Ride Control (EH) UCM Wakeup (EH) Fuel Pump (Mech) Park Brake Switch (Mech) Mechanical Backup Switch (Mech) Horn Backup Alarm (Mech) 2 Speed Switch (Mech) Hydraulic Coupler switch High Flow switch Left Hand Control Handle Brake Lamps (Mech) UCM power (multiple inputs) (EH)

1015 - Cluster Battery Monitor - Under Voltage < 11.5 volts Fuse and relay box - Testing Main Power Relay Control (A.30.A)

Fuse and relay box - Testing Option Relay Control (A.30.A) 1904 - UCM Rail 12VB 5V regulators supply Input Power OFF Fuse and relay box - Testing UCM Power Relay Control (A.30.A) (EH) Turn/hazard light - Testing Flasher Module (A.40.A) (EU)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Component identification Sensor Index NOTE: See Sensing system - Overview Temperature sensors (A.30.A) and Sensing system - Overview Speed and position sensors (A.30.A) for general sensor information. For EH machines Component Name Auxiliary Spool Position Sensor

Component ID

Frame Location

Connector

X-23 Wiring harness Electrical schematic frame 24 (A.30.A)

Boom Spool Position Sensor

X-22 Wiring harness Electrical schematic frame 24 (A.30.A)

Bucket Spool Position Sensor

Wiring harness X-21 Electrical schematic frame 24 (A.30.A)

Engine Coolant Temperature Sender

B-004 (F5C) B-012 (ISM)

Fuel Level B-001 Sender

Hydraulic Oil Temperature Sender

B-003

Wiring harness Electrical schematic frame 12 (A.30.A) (F5C) Wiring harness Electrical schematic frame 13 (A.30.A) (ISM)

X-504 (F5C) X-516 (ISM)

X-14 Wiring harness Electrical schematic frame 02 (A.30.A)

Wiring harness X-OILElectrical schematic TMP frame 02 (A.30.A)

Overview / Dynamic Description

Diagnostic

5507 - Auxiliary Valve Spool Sensor Sensor STG / OC 5508 - Auxiliary Valve Spool Sensor - Sensor STP 5513 - Auxiliary Valve Spool Sensor implausible state sensor vs auxiliary command 5501 - Loader Arm Spool Sensor Sensor STG / OC 5502 - Loader Arm Spool Sensor Sensor STP 5511 - Loader Arm Spool Sensor implausible state sensor vs loader arm command, stuck spool/PRV 5504 - Bucket Valve Spool sensor Sensor STG / OC 5505 - Bucket Valve Spool sensor Sensor STP 5512 - Bucket Valve Spool sensor implausible state sensor vs loader bucket command Sensing system 1002 - Engine Coolant Temperature Sender - Over Temperature >110° C - Overview Engine Electrical 3007 - Engine Coolant Temperature Sender - STG (B.10.A) Sensing system 3008 - Engine Coolant Temperature Sender - OC - General specification Resistance to Temperature Conversion Chart (A.30.A) Sensing system 1045 - Fuel Level Sensor - OC - Overview Engine Electrical (B.10.A) Sensing system - General specification Resistance Fuel Bar Conversion (B.20.A) Sensing system 1009 - Hydraulic Oil Temperature Sender - Over Temperature >210° F - General 4043 - Hydraulic Oil Temperature specification Sender - STG Resistance to 4044 - Hydraulic Oil Temperature Temperature Sender - OC Conversion Chart (A.30.A)

84522361 15/06/2011

A.30.A / 11

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name LH Pump Swash Plate Sensor

Component ID

Frame Location

Connector

X-94 Wiring harness Electrical schematic frame 27 (A.30.A)

RH Pump Swash Plate Sensor

X-93 Wiring harness Electrical schematic frame 27 (A.30.A)

Throttle Position Sensor

X-20 Wiring harness Electrical schematic frame 25 (A.30.A)

Overview / Dynamic Description

Diagnostic

4741 - Left Swashplate angle sensor - Pin A STG / OC 4742 - Left Swashplate angle sensor - Pin A STP 4744 - Left Swashplate angle sensor - Pin B STG / OC 4745 - Left Swashplate angle sensor - Pin B STP 4747 - Left Swashplate angle sensor - in-range fault 4752 - Left Swashplate angle sensor - Implausible command, command does not match with swashplate angle 4731 - Right Swashplate angle sensor - Pin A STG / OC 4732 - Right Swashplate angle sensor - Pin A STP 4734 - Right Swashplate angle sensor - Pin B STG / OC 4735 - Right Swashplate angle sensor - Pin B STP 4737 - Right Swashplate angle sensor - in-range fault 4754 - Right Swashplate angle sensor - Implausible command, command does not match with swashplate angle Sensing system 1025 - Throttle Sensor - out of range - Overview STP Engine Electrical 1030 - Throttle Sensor - out of range (B.10.A) STG/OC

For Mechanical machines Component Name Engine Coolant Temperature Sender

Component ID B-004 (F5C) B-012 (ISM)

Fuel Level B-001 Sender

Frame Location

Wiring harness Electrical schematic frame 12 (A.30.A) (F5C) Wiring harness Electrical schematic frame 13 (A.30.A) (ISM)

Connector X-504 (F5C) X-516 (ISM)

X-14 Wiring harness Electrical schematic frame 02 (A.30.A)

Overview / Dynamic Description Sensing system - Overview Engine Electrical (B.10.A) Sensing system - General specification Resistance to Temperature Conversion Chart (A.30.A) Sensing system - Overview Engine Electrical (B.10.A) Sensing system - General specification Resistance Fuel Bar Conversion (B.20.A)

84522361 15/06/2011

A.30.A / 12

Diagnostic

1002 - Engine Coolant Temperature Sender - Over Temperature >110° C 3007 - Engine Coolant Temperature Sender - STG 3008 - Engine Coolant Temperature Sender - OC

1045 - Fuel Level Sensor - OC

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name Hydraulic Oil Temperature Sender

Component ID B-002

Frame Location

Connector

Wiring harness X-OILElectrical schematic TMP frame 02 (A.30.A)

Overview / Dynamic Description Sensing system - General specification Resistance to Temperature Conversion Chart (A.30.A)

84522361 15/06/2011

A.30.A / 13

Diagnostic

1009 - Hydraulic Oil Temperature Sender - Over Temperature >210° F 4043 - Hydraulic Oil Temperature Sender - STG 4044 - Hydraulic Oil Temperature Sender - OC

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Component identification Motor Index NOTE: See ELECTRICAL POWER SYSTEM - Overview Resistance devices (A.30.A) for resistive device information. Component Name

Component ID

G-026 (F5C) G-027 (ISM)

Door Wiper Motor

Front Door Washer Pump

HVAC Condenser Fan

Rear Wiper Motor

Connector

Wiring harness X-AC_COMP - Electrical schematic frame 17 (A.30.A)

A/C Compressor

Alternator

Frame Location

M-506

Wiring harness X-5 - Electrical schematic frame 12 (A.30.A) (F5C) Wiring harness - Electrical schematic frame 13 (A.30.A) (ISM)

Wiring harness X-502 - Electrical schematic frame 09 (A.30.A) Wiring harness X-506 - Electrical schematic frame 09 (A.30.A) Wiring harness X-74 - Electrical schematic frame 17 (A.30.A)

Wiring harness X-502A - Electrical schematic frame 09 (A.30.A)

84522361 15/06/2011

A.30.A / 14

Overview / Dynamic Description ENVIRONMENT CONTROL Air-conditioning system Overview HVAC System (E.40.C)

Diagnostic

ENVIRONMENT CONTROL Air-conditioning system Overview HVAC System (E.40.C)

Fuse and relay box - Testing Condenser Relay Control (A.30.A) Condenser Testing HVAC Condenser Fan (E.40.C) ENVIRONMENT CONTROL Air-conditioning system Problem solving HVAC (E.40.C)

Compressor - Testing A/C Compressor (E.40.C) ENVIRONMENT CONTROL Air-conditioning system Problem solving HVAC (E.40.C) 1041 - RPM Start control Monitoring - Overview Ignition System Over Speed 1202 - RPM (B.80.A) Monitoring Over Speed (Max) 1203 - RPM Monitoring Open Circuit / STG / STP

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name

Component ID

Starter Motor

Water Valve

Z-019

Frame Location

Connector

Wiring harness X-513 (F5C) - Electrical X-C126 (ISM) schematic frame 12 (A.30.A) (F5C) Wiring harness - Electrical schematic frame 13 (A.30.A) (ISM) Wiring harness X-271 - Electrical schematic frame 17 (A.30.A)

84522361 15/06/2011

A.30.A / 15

Overview / Dynamic Description Start control - Overview Ignition System (B.80.A)

ENVIRONMENT CONTROL Air-conditioning system Overview HVAC System (E.40.C)

Diagnostic

3404 - Starter STP 3405 - Starter STG / OC

Electronic A/C control - Testing HVAC Heat Components (E.40.C) ENVIRONMENT CONTROL Air-conditioning system Problem solving HVAC (E.40.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Component identification Solenoid Index NOTE: See ELECTRICAL POWER SYSTEM - Overview Solenoids (A.30.A) for general solenoid information. Component CompoName nent ID 2 Speed Solenoid Y-005

2nd Aux Extend Solenoid

2nd Aux Retract Solenoid

Frame Location Wiring harness - Electrical schematic frame 07 (A.30.A)

Wiring harness - Electrical schematic frame 15 (A.30.A) Wiring harness - Electrical schematic frame 15 (A.30.A) Wiring harness - Electrical schematic frame 28 (A.30.A) (EH) Wiring harness - Electrical schematic frame 02 (A.30.A) (Mech)

Connector X-2SPD

Overview / Dynamic Description

X-AUX_ EXT

Diagnostic 4781 - solenoid valve Solenoid Supply OC (EH) 4782 - solenoid valve Solenoid Supply STG (EH) 4783 - solenoid valve - Solenoid Supply STP (EH) Control valve - Testing 2nd Aux Extend Solenoid (G.90.C)

X-AUX_ RET

Control valve - Testing 2nd Aux Retract Solenoid (G.90.C)

X-BRK

4055 - Park Brake Valve (On/Off) - Solenoid Supply OC (EH) 4056 - Park Brake Valve (On/Off) - Solenoid Supply STG (EH) 4057 - Park Brake Valve (On/Off) - Solenoid Supply STP (EH) 4401 - Park Brake (Mechanical Machines) - Park Brake Solenoid OC (Mech) 4402 - Park Brake (Mechanical Machines) - Park Brake Solenoid STP (Mech) 5251 - Loader Bucket Valve (Directional) Solenoid rollback (A) Supply OC 5252 - Loader Bucket Valve (Directional) Solenoid rollback (A) Supply STG (EH) 5271 - Bucket Valve (Directional) - Common Solenoid (C) Return STP (EH) 5272 - Loader Bucket Valve (Directional) Loader Bucket Solenoids STG (EH) 5273 - Bucket Valve (Directional) - Common Solenoid (C) Return OC (EH)

Brake Valve Solenoid

Y-008

Bucket Valve Extend Solenoid (EH)

X-26 (EH) Y-006 (EH) Wiring harness - Electrical schematic frame 24 (A.30.A) (EH)

84522361 15/06/2011

A.30.A / 16

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Frame Location Connec- Overview / Dynamic Component Compotor Description Name nent ID Bucket Valve X-25 (EH) Y-003 (EH) Wiring harness - Electrical Retract Solenoid schematic frame (EH) 24 (A.30.A) (EH)

EHF Extend Solenoid (EH)

EHF Retract Solenoid (EH)

Fuel Solenoid

Hydraulic Coupler Y-013 Solenoid

Wiring harness - Electrical schematic frame 32 (A.30.A) (EH) Wiring harness - Electrical schematic frame 32 (A.30.A) (EH) Wiring harness - Electrical schematic frame 12 (A.30.A) (F5C) Wiring harness - Electrical schematic frame 13 (A.30.A) (ISM) Wiring harness - Electrical schematic frame 25 (A.30.A) (EH) Wiring harness - Electrical schematic frame 02 (A.30.A) (Mech)

Diagnostic 5261 - Bucket Valve (Directional) - Solenoid dump (B) Supply OC 5262 - Bucket Valve (Directional) - Solenoid dump (B) Supply STG (EH) 5271 - Bucket Valve (Directional) - Common Solenoid (C) Return STP (EH) 5272 - Loader Bucket Valve (Directional) Loader Bucket Solenoids STG (EH) 5273 - Bucket Valve (Directional) - Common Solenoid (C) Return OC (EH)

X-19 (EH)

X-40 (EH)

X-FUEL (F5C) X-510 (ISM)

Start control Overview Ignition System (B.80.A)

X-CPLR

84522361 15/06/2011

A.30.A / 17

3401 - Engine Start - Fuel Solenoid - STP 3402 - Engine Start - Fuel Solenoid - OC

Electrical control Testing Hydraulic Coupler Switch and Solenoid (J.80.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name Left Drive Pump Forward Solenoid (EH)

Left Drive Pump Reverse Solenoid (EH)

Loader Pilot Interlock Solenoid (EH)

Component ID

Diagnostic Connec- Overview / Dynamic tor Description 4071 - Forward Wiring harness X-13 (EH) Pump Control Valves - Electrical (Directional) - Solenoid schematic frame Left (B) Supply OC 27 (A.30.A) (EH) 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply STG (EH) 4081 - Forward Pump Control Valves (Directional) - Common Solenoid Return STP (EH) 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return OC (EH) 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply STG (EH) Wiring harness 4371 - Reverse X-16 (EH) - Electrical Pump Control Valves schematic frame (Directional) - Solenoid 27 (A.30.A) (EH) Left (B) Supply OC 4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply STG (EH) 4381 - Reverse Pump Control Valves (Directional) - Common Solenoid Return STP (EH) 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids STG (EH) 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return OC (EH) X-PLTL5051 - Loader Pilot Wiring harness K(EH) Interlock Valve (On/Off) - Electrical Solenoid Supply OC schematic frame 5052 - Loader Pilot 15 (A.30.A) (EH) Interlock Valve (On/Off) - Solenoid Supply STG (EH) 5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply STP (EH) Frame Location

84522361 15/06/2011

A.30.A / 18

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name Loader Port Lock Solenoid

Loader Valve Extend Solenoid (EH)

Component ID

Frame Location Wiring harness - Electrical schematic frame 15 (A.30.A)

Connector X-PORT_LK

Overview / Dynamic Description

X-28 (EH) Y-009 (EH) Wiring harness - Electrical schematic frame 24 (A.30.A)(EH)

Loader Valve X-27 (EH) Y-007 (EH) Wiring harness - Electrical Retract Solenoid schematic frame (EH) 24 (A.30.A) (EH)

84522361 15/06/2011

A.30.A / 19

Diagnostic 5061 - Port Lock Valve (On/Off) - Solenoid Supply OC 5062 - Port Lock Valve (On/Off) - Solenoid Supply STG (EH) 5063 - Port Lock Valve (On/Off) - Solenoid Supply STP (EH) 5221 - Loader Arm Valve (Directional) - Solenoid Raise A Supply OC 5222 - Loader Arm Valve (Directional) - Solenoid Raise A Supply STG (EH) 5241 - Boom Valve (Directional) - Common Solenoid (C) Return STP (EH) 5242 - Loader Arm Valve (Directional) - Loader Arm Solenoids STG (EH) 5243 - Boom Valve (Directional) - Common Solenoid (C) Return OC (EH) 5231 - Loader Arm Valve (Directional) - Solenoid Lower B Supply OC 5232 - Loader Arm Valve (Directional) - Solenoid Lower B Supply STG (EH) 5241 - Boom Valve (Directional) - Common Solenoid (C) Return STP (EH) 5242 - Loader Arm Valve (Directional) - Loader Arm Solenoids STG (EH) 5243 - Boom Valve (Directional) - Common Solenoid (C) Return OC (EH)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name Proportional Aux Valve Extend Solenoid

Component ID

Proportional Aux Valve Retract Solenoid

Ride Control Solenoid

Y-010

Frame Location

Connec- Overview / Dynamic tor Description Wiring harness X-24 (EH) - Electrical X-433 schematic frame (Mech) 24 (A.30.A) (EH) Wiring harness - Electrical schematic frame 19 (A.30.A) (Mech)

Diagnostic

5281 - Aux Valve (Directional) - Solenoid Forward (A) Supply OC (EH) 5282 - Aux Valve (Directional) - Solenoid Forward (A) Supply STG (EH) 5601 - Aux Valve (Directional) - Common Solenoid Return STP (EH) 5602 - Loader Auxiliary Valve (Directional) - Loader Auxiliary Solenoids STG (EH) 5603 - Loader Auxiliary Valve (Directional) Solenoids Return OC (EH) 5291 - Aux Valve Wiring harness X-29 (EH) (Directional) - Solenoid - Electrical X-432 Reverse (B) Supply OC schematic frame (Mech) (EH) 24 (A.30.A) (EH) 5292 - Aux Valve Wiring harness (Directional) - Solenoid - Electrical Reverse (B) Supply STG schematic frame (EH) 19 (A.30.A) (Mech) 5601 - Aux Valve (Directional) - Common Solenoid Return STP (EH) 5602 - Loader Auxiliary Valve (Directional) - Loader Auxiliary Solenoids STG (EH) 5603 - Loader Auxiliary Valve (Directional) Solenoids Return OC (EH) Wiring harness X-RDC- Command - Overview Command - Testing Glide - Electrical TRL Glide Ride control Ride Control Solenoid schematic frame (D.15.C) and Switch (D.15.C) 28 (A.30.A) (EH) Wiring harness - Electrical schematic frame 07 (A.30.A) (Mech)

84522361 15/06/2011

A.30.A / 20

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name RH Drive Pump Forward Solenoid (EH)

Component ID

Right Drive Pump Reverse Solenoid (EH)

Std High Flow Solenoid

Y-004

Diagnostic Connec- Overview / Dynamic tor Description 4061 - Forward Wiring harness X-17 (EH) Pump Control Valves - Electrical (Directional) - Solenoid schematic frame Right (A) Supply OC 27 (A.30.A) (EH) 4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply STG (EH) 4081 - Forward Pump Control Valves (Directional) - Common Solenoid Return STP (EH) 4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids STG (EH) 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return OC (EH) 4361 - Reverse Wiring harness X-18 (EH) Pump Control Valves - Electrical (Directional) - Solenoid schematic frame Right (A) Supply OC (EH) 27 (A.30.A) (EH) 4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply STG (EH) 4381 - Reverse Pump Control Valves (Directional) - Common Solenoid Return STP (EH) 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids STG (EH) 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return OC (EH) Hydraulic line - Testing Wiring harness X-HFLO Std High Flow Solenoid - Electrical (H.20.B) schematic frame 25 (A.30.A) (EH) Wiring harness - Electrical schematic frame 02 (A.30.A) (Mech) Frame Location

84522361 15/06/2011

A.30.A / 21

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Component identification Diode Index NOTE: See ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A) for general diode testing. Component Name Accessory Backfeed Diode

Component ID V-004

EH Lap Bar Diode (EH)

V-005 (EH)

EH Seat Sw UCM Diode (EH)

V-009 (EH)

EH UCM Wakeup Diode (EH)

V-006 (EH)

Hazard Switch Indicator Backfeed Diode (EU)

V-010 (EU)

Ignition Backfeed Diode

V-007

Frame Location Wiring harness Electrical schematic frame 03 (A.30.A) Wiring harness Electrical schematic frame 20 (A.30.A) Wiring harness Electrical schematic frame 20 (A.30.A)

Connector X-15-A (EH) X-15-B (EH) X-15 (Mech) X-99 (EH)

X-98 (EH)

Wiring harness X-298 (EH) Electrical schematic frame 20 (A.30.A) Wiring harness X-HZRDDIODE (EU) Electrical schematic frame 16 (A.30.A) (EU) X-316 Wiring harness Electrical schematic frame 04 (A.30.A)

84522361 15/06/2011

A.30.A / 22

Other Information

Diagnostic Trouble Code resolution 1208 - Seat Switch Plausibility Fault (EH)

Turn/hazard light Testing Turn Signal Switch (A.40.A) (EU) Start control Overview Ignition System (B.80.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Component identification Lighting Index NOTE: See ELECTRICAL POWER SYSTEM - Overview Resistance devices (A.30.A) for resistive device information. Component Name

Component ID

Frame Location

Connector

Wiring harness X-310 - Electrical schematic frame 14 (A.30.A)

2 Speed Indicator

Dome Lamp

E-003

LH Front Road Lamp

E-021 E-027 E-028

LH Front Strobe

E-023

LH Rear Road Lamp

E-037 E-038 E-198

LH Rear Strobe

E-021

LH Rear Work

E-033

RH Front Road Lamp

E-011 E-017 E-018

RH Front Strobe

E-024

RH Rear Road Lamp

E-196 E-044 E-045

RH Rear Strobe

E-025

Wiring harness - Electrical schematic frame 21 (A.30.A) (EH) Wiring harness - Electrical schematic frame 08 (A.30.A) (Mech) Wiring harness - Electrical schematic frame 18 (A.30.A) Wiring harness - Electrical schematic frame 08 (A.30.A) Wiring harness - Electrical schematic frame 18 (A.30.A) Wiring harness - Electrical schematic frame 08 (A.30.A) Wiring harness - Electrical schematic frame 08 (A.30.A) Wiring harness - Electrical schematic frame 18 (A.30.A) Wiring harness - Electrical schematic frame 08 (A.30.A) Wiring harness - Electrical schematic frame 18 (A.30.A) Wiring harness - Electrical schematic frame 08 (A.30.A)

X-97

X-228

X-344

X-37

X-341

X-34

X-229

X-343

X-196

X-342

84522361 15/06/2011

A.30.A / 23

Overview / Dynamic Description Command Overview 2 Speed Switch (D.15.C)

Diagnostic

Command - Testing 2 Speed Switch and Indicator (D.15.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name RH Rear Work

Component ID

E-038

Rotating Beacon

Turn Signal Indicator

Z-2011

Frame Location

Wiring harness - Electrical schematic frame 08 (A.30.A) Wiring harness - Electrical schematic frame 08 (A.30.A) Wiring harness - Electrical schematic frame 14 (A.30.A)

Connector

X-35

X-178

X-155B X-156B X-157B

84522361 15/06/2011

A.30.A / 24

Overview / Dynamic Description

Diagnostic

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Component identification Miscellaneous Index Com- Frame Location Connector ponent ID Accessory Z-008 Wiring harness X-ACC Power Outlet - Electrical schematic frame 06 (A.30.A) Z-FU- Wiring harness Accessory SE2 - Electrical Power schematic frame Distribution 05 (A.30.A) Fuse Block #2 (EH) Accessory Power Distribution (Mech) Backup Alarm H-002 Wiring harness X-BKUP- Electrical GND schematic frame X-BKUP04 (A.30.A) PWR Battery Wiring harness X-EH_POS1 - Electrical schematic frame X-EH_POS2 (EH) 10 (A.30.A) X-POS_ TERM_B (Mech) Wiring harness X-DIAG CAN - Electrical Diagnostic schematic frame Connector 31 (A.30.A) (EH) Wiring harness - Electrical schematic frame 25 (A.30.A) (Mech) Wiring harness X-EGR ECU (F5C) - Electrical (F5C) schematic frame 12 (A.30.A) (F5C) EH Aux PWM U-001 Wiring harness X-430 (Mech) Controller (Mech) - Electrical (Mech) schematic frame 19 (A.30.A) (Mech) Wiring harness X-67 (EH) EHF Pressure - Electrical Transducer schematic frame (EH) 32 (A.30.A) (EH) Horn H-009 Wiring harness X-HORN- Electrical GND schematic frame X-HORN07 (A.30.A) PWR Component Name

Overview / Dynamic Description

Diagnostic

Cigar lighter - Testing Accessory Power Outlet (E.34.A)

Fuse and relay box - General specification Accessory Power Distribution (A.30.A)

1531 - Backup Alarm - OC (EH) 1532 - Backup Alarm - STG (EH)

Battery - Check Maintenance Free (A.30.A)

Sensing system - 3000 - Engine Malfunction - ECU Overview Engine Fault - General/Undefined/Air Filter Electrical (B.10.A) Restriction (F5C) (F5C)

84522361 15/06/2011

A.30.A / 25

Audible alert - Testing Horn (E.50.B)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name

HVAC Box

Com- Frame Location Connector ponent ID A-003 Wiring harness X-HVC2 - Electrical schematic frame 17 (A.30.A)

Instrument Cluster

Wiring harness - Electrical schematic frame 03 (A.30.A) Wiring harness - Electrical schematic frame 07 (A.30.A)

Left Hand Control Handle

Z-005

Main Power Distribution Fuse Block 1

Z-2008 Wiring harness - Electrical schematic frame 04 (A.30.A)

Multifunction Attachment Connector

X-C23

Overview / Dynamic Description

Diagnostic

ENVIRONMENT CONTROL Air-conditioning system Overview HVAC System (E.40.C) Electronic service tool (EST) Overview EST overview (A.50.A)

Electronic A/C control - Testing HVAC Box (E.40.C) ENVIRONMENT CONTROL Air-conditioning system - Problem solving HVAC (E.40.C) Data bus - General specification Instrument Cluster pin information (A.50.A) 5201 - L joystick L-R axis - Pin A STP / STG / OC (EH) 5202 - L joystick L-R axis - Pin B STP / STG / OC (EH) 5204 - L joystick L-R axis - in-range fault (EH) 5211 - L joy F-B axis - Pin A STG / OC (EH) 5212 - L joy F-B axis - Pin A STP (EH) 5214 - L joy F-B axis - Pin B STG / OC (EH) 5215 - L joy F-B axis - Pin B STP (EH) 5217 - L joy F-B axis - in-range fault (EH)

X-178 (EH) X-155B (Mech) X-156B (Mech) X-157B (Mech)

Fuse and relay box - General specification Main Power Distribution Fuse Block 1 (A.30.A)

Wiring harness X-107 - Electrical schematic frame 29 (A.30.A) (EH) Wiring harness - Electrical schematic frame 24 (A.30.A) (Mech)

84522361 15/06/2011

A.30.A / 26

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name

Right Hand Control Handle

Com- Frame Location ponent ID Z-012 Wiring harness - Electrical schematic frame 07 (A.30.A) Wiring harness - Electrical schematic frame 19 (A.30.A) (EH) Wiring harness - Electrical schematic frame 23 (A.30.A) (Mech)

Seat Heat Element

R-001

Self Level Valve

Y-318

Side Lamp DIA Socket

Telematics Connector

Connector

Overview / Dynamic Description

5121 - R joy F-B axis - Pin A STP / STG / OC (EH) 5122 - R joy F-B axis - Pin B STP / STG / OC (EH) 5124 - R joy F-B axis - in-range fault (EH) 5131 - R joy R-L axis (ISO/H Pattern) - Pin A STG / OC (EH) 5132 - R joy R-L axis (ISO/H Pattern) - Pin A STP (EH) 5134 - R joy R-L axis (ISO/H Pattern) - Pin B STG / OC (EH) 5135 - R joy R-L axis (ISO/H Pattern) - Pin B STP (EH) 5137 - R joy R-L axis (ISO/H Pattern) - in-range fault (EH) 5141 - Aux thumbwheel axis - Pin A STG / OC (EH) 5142 - Aux thumbwheel axis - Pin A STP (EH) 5144 - Aux thumbwheel axis - Pin B STG / OC (EH) 5145 - Aux thumbwheel axis - Pin B STP (EH) 5147 - Aux thumbwheel axis in-range fault (EH) Heater - Testing Seat Heat Switch (E.32.C)

X-403 (EH) X-406 (EH) X-403 (Mech) X-406 (Mech)

Wiring harness - Electrical schematic frame 20 (A.30.A) Wiring harness X-318 - Electrical schematic frame 02 (A.30.A) Wiring harness X-77 - Electrical schematic frame 08 (A.30.A) Wiring harness X-TELE - Electrical schematic frame 30 (A.30.A) (EH) Wiring harness - Electrical schematic frame 26 (A.30.A) (Mech)

Diagnostic

Command Overview Self Level (D.15.C)

84522361 15/06/2011

A.30.A / 27

Command - Testing Self Level Switch and Valve (D.15.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Com- Frame Location Connector ponent ID Temp Control Z-017 Wiring harness X-252 - Electrical LH Console schematic frame 17 (A.30.A) Component Name

UCM (EH)

A-002 (EH)

Wiring harness - Electrical schematic frame 26 (A.30.A) (EH)

Overview / Dynamic Description

Diagnostic

ENVIRONMENT CONTROL Air-conditioning system Overview HVAC System (E.40.C) ELECTRICAL POWER SYSTEM - Overview Potentiometers (A.30.A)

Electronic A/C control - Testing HVAC Heat Components (E.40.C) ENVIRONMENT CONTROL Air-conditioning system - Problem solving HVAC (E.40.C)

X-CN1A X-CN1B X-CN2A X-CN2B X-CN3A X-CN3B X-CN4A X-CN4B (EH)

84522361 15/06/2011

A.30.A / 28

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Component identification Switch Index NOTE: See ELECTRICAL POWER SYSTEM - Overview Switches (A.30.A) for general switch information. Component Name

Component ID

Frame Location

Connector

2 Speed Switch

S-024

Wiring harness X-406 (EH) - Electrical X-405 (Mech) schematic frame 07 (A.30.A)

2nd Aux Hyd Switch

S-033

AC Switch Left Console

S-017

Wiring harness X-406 (EH) - Electrical X-405 (Mech) schematic frame 07 (A.30.A) Wiring harness X-275 - Electrical schematic frame 17 (A.30.A)

Air Filter Restriction Switch

Blower Switch Left Console

S-020

Brake Pressure Switch

S-039 (EH) S-036 (Mech)

Charge Pressure B-009 (EH) Switch (EH)

Wiring harness X-508 - Electrical schematic frame 12 (A.30.A) (F5C) Wiring harness - Electrical schematic frame 13 (A.30.A) (ISM) Wiring harness X-270 - Electrical schematic frame 17 (A.30.A)

Wiring harness - Electrical schematic frame 28 (A.30.A) (EH) Wiring harness - Electrical schematic frame 05 (A.30.A) (Mech) Wiring harness - Electrical schematic frame 28 (A.30.A) (EH)

X-BRKPRS (EH) X-161 (Mech) X-162 (Mech) X-163 (Mech) X-164 (Mech)

X-CHGPRS (EH)

84522361 15/06/2011

A.30.A / 29

Overview / Dynamic Description Command Overview 2 Speed Switch (D.15.C)

ENVIRONMENT CONTROL Air-conditioning system Overview HVAC System (E.40.C)

Sensing system - Overview Engine Electrical (B.10.A)

ENVIRONMENT CONTROL Air-conditioning system Overview HVAC System (E.40.C)

Diagnostic

Command - Testing 2 Speed Switch and Indicator (D.15.C) Control valve - Testing 2nd Aux Hyd Switch (G.90.C) Electronic A/C control - Testing A/C Switch (E.40.C) ENVIRONMENT CONTROL Air-conditioning system Problem solving HVAC (E.40.C) 3000 - Engine Malfunction - ECU Fault - General/ Undefined/Air Filter Restriction

Electronic A/C control - Testing Blower Switch (E.40.C) ENVIRONMENT CONTROL Air-conditioning system Problem solving HVAC (E.40.C) 4431 - Park Brake Pressure Switch Pressure Switch (plausibility check with solenoid valve) (EH)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name

Component ID

Frame Location

Connector

Door Switch

Wiring harness X-505 - Electrical schematic frame 09 (A.30.A)

Drive Pattern Selector Switch (EH)

Wiring harness X-95 (EH) - Electrical schematic frame 06 (A.30.A) (EH)

Electric Aux Hyd On / Off Switch

Wiring harness X-304 - Electrical schematic frame 06 (A.30.A)

Engine Oil Press Switch

Wiring harness X-510 (F5C) - Electrical X-512 (ISM) schematic frame 12 (A.30.A) (F5C) Wiring harness - Electrical schematic frame 13 (A.30.A) (ISM)

Float Button (EH) S-007 (EH)

Wiring harness - Electrical schematic frame 19 (A.30.A) (EH) Wiring harness - Electrical schematic frame 06 (A.30.A) Wiring harness - Electrical schematic frame 06 (A.30.A) Wiring harness - Electrical schematic frame 07 (A.30.A) Wiring harness - Electrical schematic frame 17 (A.30.A)

Hazard Lamp Switch

High Flow Switch

Horn Switch

S-023

HVAC High Pressure Switch

Hydraulic Coupler S-009 Switch

X-403 (EH)

X-302

X-303

X-406 (EH) X-405 (Mech)

X-76

Wiring harness X-300 - Electrical schematic frame 06 (A.30.A)

84522361 15/06/2011

A.30.A / 30

Overview / Dynamic Description Door, window and windscreen - Overview Door Switch - Overview (E.34.A) PRIMARY HYDRAULIC POWER SYSTEM Overview EH Drive Pattern Selector Switch (A.10.A) (EH)

Diagnostic

Door, window and windscreen - Testing Door Switch (E.34.A)

5701 - Pattern Switch - STG / OC (EH) 5703 - Pattern Switch - STP (EH)

Auxiliary power connection Testing Electric Auxiliary Hydraulic On/Off Switch (A.30.A) Sensing system 3028 - Engine Oil Pressure - Overview Engine Electrical Switch - Engine Oil Pressure (B.10.A) Low 3029 - Engine Oil Pressure Switch - Engine Oil Pressure Switch OC 5309 - Float Button - Float Button Timeout (30 sec) (EH) Turn/hazard light - Testing Hazard Lamp Switch (A.40.A) Control valve - Control valve Overview High - Testing High Flow Switch Flow (G.90.C) (G.90.C) Audible alert Testing Horn (E.50.B) ENVIRONMENT CONTROL Air-conditioning system Overview HVAC System (E.40.C)

Sensing system - Testing HVAC High Pressure Switch (E.40.C)

Electrical control - Testing Hydraulic Coupler Switch and Solenoid (J.80.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name

Component ID

Frame Location

Connector

Hydraulic Enable Switch

Hydraulic Filter B-010 Restriction Switch

Wiring harness X-OILFLT - Electrical schematic frame 02 (A.30.A)

Ignition Switch

Wiring harness X-9 - Electrical schematic frame 14 (A.30.A) Wiring harness X-311 - Electrical schematic frame 08 (A.30.A)

Lamp Selector Switch

S-012

Loader Lockout Switch

S-005

Mechanical Backup Switch #1 (Mech)

S-004 (Mech)

Mechanical Backup Switch #2 (Mech)

S-005 (Mech)

NH Park Brake Switch

Operator Restraint Switch

Wiring harness - Electrical schematic frame 06 (A.30.A) Wiring harness - Electrical schematic frame 04 (A.30.A) (Mech) Wiring harness - Electrical schematic frame 04 (A.30.A) (Mech) Wiring harness - Electrical schematic frame 06 (A.30.A)

X-306

Overview / Dynamic Description Command - Overview Hydraulic Enable Switch - Overview (A.14.A)

Diagnostic

1004 - Hydraulic Filter Restriction Switch Hydraulic Filter Restricted 1201 - Hydraulic Filter Restriction Switch - OC Start control Start control Testing Ignition - Overview Ignition System Switch (B.80.A) (B.80.A) LIGHTING LIGHTING SYSTEM SYSTEM Testing Lamp Overview Lighting (A.40.A) Selector Switch (A.40.A) Control valve - Control valve Overview loader Testing Loader lock control Lockout Switch valve (H.20.B) (H.20.B)

X-42 (Mech)

X-43 (Mech)

X-365

Wiring harness X-104 - Electrical schematic frame 20 (A.30.A)

84522361 15/06/2011

A.30.A / 31

Electrical control Overview Park Brake (D.32.C)

4309- Park Brake Button - Park Brake Button Timeout (30 sec) (D.32.C) (EH) Command Testing Operator Restraint Switch (E.32.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name

Component ID

Frame Location

Connector

Proportional Aux Switch (EH)

S-036 S-037 (EH)

Wiring harness X-403 (EH) - Electrical schematic frame 19 (A.30.A) (EH)

Proportional Auxiliary Hydraulic Switch (Mech)

U-004 (Mech)

Wiring harness X-402 (Mech) - Electrical schematic frame 23 (A.30.A) (Mech) Wiring harness X-406 (EH) - Electrical X-402 (Mech) schematic frame 07 (A.30.A)

Ride Control / S-018 Glide Ride Switch

Rotating Beacon Switch

S-001

Seat Heat Switch S-003

Seat Switch

S-002

Self Level Switch S-013

STD / On Road Lamp Configurator Turn Signal Switch

S-029

Wiring harness X-301 - Electrical schematic frame 06 (A.30.A) Wiring harness X-58 - Electrical schematic frame 20 (A.30.A) Wiring harness X-58 - Electrical schematic frame 20 (A.30.A)

Wiring harness - Electrical schematic frame 06 (A.30.A) Wiring harness - Electrical schematic frame 02 (A.30.A) Wiring harness - Electrical schematic frame 07 (A.30.A)

Overview / Dynamic Description

Diagnostic

5141 - Aux thumbwheel axis - Pin A STG / OC (EH) 5142 - Aux thumbwheel axis - Pin A STP (EH) 5144 - Aux thumbwheel axis - Pin B STG / OC (EH) 5145 - Aux thumbwheel axis - Pin B STP (EH) 5147 - Aux thumbwheel axis - in-range fault (EH)

Command Overview Glide Ride control (D.15.C)

Command Testing Glide Ride Control Solenoid and Switch (D.15.C)

Heater - Testing Seat Heat Switch (E.32.C) 1208 - Seat Switch Plausibility Fault (EH) Command Testing Seat Switch (E.32.C)

X-317

X-101 X-101A X-101B X-406 (EH) X-407 (Mech)

84522361 15/06/2011

A.30.A / 32

Turn/hazard light - Testing Turn Signal Switch (A.40.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name Wiper / Washer Switch

Component ID

S-016

Frame Location

Connector

Wiring harness X-503 - Electrical schematic frame 09 (A.30.A)

84522361 15/06/2011

A.30.A / 33

Overview / Dynamic Description

Diagnostic

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Overview An electrical circuit is comprised of three basic elements; a source of electrical energy which provides the current used by the electrical circuit, a load which converts the electrical current into a work form such as heat or light or an electromagnetic energy field and conductors which are used to route the electrical current from the source to the load and back to the source. The device used to provide the electrical current in a direct current (DC) circuit is typically a battery. The battery uses a chemical action to create and store the needed electrical energy. An alternator which converts mechanical energy into electrical energy and is driven by an engine is used to recharge the battery. Load devices are designed to utilize the two natural products created when electrical current flows through a conductive material, that being heat and a magnetic field. Lamps heat alloyed conductive materials to a temperature that produces visible light where as heater elements use an alloyed material to produce heat. Solenoids and motors use the magnetic field produced by the current flow to attract or repel ferrous material and produce linear or rotary motion. Stranded or solid copper or copper clad wire is used to conduct the electrical current between the source and the loads. The return path to the source from the loads in battery sourced systems is often the metallic materials that are the components of the machine or what is referred to as frame or chassis ground. The negative terminal on the battery is then connected to the frame or chassis, thus completing the electrical circuit. In addition to the basic elements required in a electrical circuit, most also contain protective devices, fuses or circuit breakers, that are designed to interrupt the current flow should it exceed the amount the conductors or loads in the circuit are capable of handling without damage. An electrical control scheme is comprised of three categories of devices; input devices like switches, potentiometers and sensors, control or logic devices like relays and programmed or programmable electronic modules and output devices like lights, motors and solenoids. Input devices provide information in the way of an electrical signal to the logic devices. The signal provided may be a digital signal; on or off, high or low, a transition from one predefined level to another either higher or lower which is referred to as leading or trailing edge or an analog signal which is variable measurable levels. Logic or control devices use the signals provided by the input devices to determine how the output devices should be controlled, energized or de-energized and to what level and polarity. Programmed and programmable logic devices often use the system source voltage, battery voltage, to create other voltages which are referred to as reference voltages. The reference voltage or reference source as well as a reference ground or control module ground is provided by the logic or control device to inputs and outputs. This means the control or logic device is capable of switching, sensing or varying different signal levels and types. Configuring the electrical control scheme is done in a variety of ways. The input devices may use: •

system source, which is the battery, or

•

system ground, which is the frame or chassis, or

•

a reference voltage, which is created by the control module, or

•

a reference ground, which is provided by the control module,

to provide a digital or analog signal to the control or logic device.

•

A single input device may provide a signal directly or

•

two or more input devices sharing the same signal wire, in parallel, may provide the signal or

•

two or more input devices may provide the signal through one another, in series,

to the control or logic device.

84522361 15/06/2011

A.30.A / 34

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Overview Potentiometers Potentiometers are also a vital part of an electric circuit. Typically potentiometers are configured to provide operator or operational information to an electronic controller. Unlike switches, which are used to provide digital input (on or off type of signal), potentiometers provide an analog input (variable type of signal). Some potentiometers are operator controlled, like the radio volume control knob or the temperature and fan speed control knobs on the HVAC control module, but the majority use of potentiometers is to provide operational information, such as fluid levels or product flow (volume) or device location (position) information.

20095585

1

The Fuel level sensing device contains a potentiometer (1) that is attached to the fuel return (2) and supply (not used) (3) tubes and controlled by the movement of a float (4) attached to the potentiometer actuator arm (5).

93095586

2

Rotary to linear actuators contain a potentiometer used to provide position information.

1z0o2004112130

3

Like operator and mechanically controlled switches, checking the operation of potentiometers can be accomplished by disconnecting the potentiometer from the electrical circuit and using a multi-meter to measure resistances. Potentiometers are three-wire devices. Typically a source voltage is connected to one of the pins attached to the stationary (fixed contact) resistive component of the potentiometer and reference ground to the other while the signal is taken from the pin attached to the wiper (movable contact). First measure the resistance across the full range of the potentiometer, the pins attached to the stationary (fixed contact) resistive component of the potentiometer and then from either end to the pin attached to the wiper (movable contact). In the latter test the resistance value should change, 84522361 15/06/2011

A.30.A / 35

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

continuously and smoothly, as the wiper is manually moved. As the resistance varies with temperature, the test specifications are usually given at 20 °C (68 °F). NOTE: Like switches a growing number of potentiometers, as well as other variable resistive devices, are incorporating electronics. These devices are referred to as Sensors rather than Potentiometers or Varistors and often cannot be continuity tested with a multi-meter.

Potentiometer Adjustment When installing potentiometers, it is important to ensure that they do not bottom out in either direction, to prevent damage. Most potentiometers have slotted mounting holes to allow some adjustment. Before tightening the mounting hardware, operate the attaching linkage fully in both directions to confirm proper potentiometer positioning.

84522361 15/06/2011

A.30.A / 36

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Overview Switches Switches are a vital part of an electric circuit. Switches may be configured to provide operator or operational information to an electronic controller or switches may be used to control circuit operation indirectly by energizing a control relay or switches may control the operation of a functional device directly by completing the power or ground side of the control circuit. Switches can be configured to control a number of different functional devices at the same time and / or multiple functional devices one at a time. This is achieved by having several separate functional devices connected to a single switch terminal or by having each of the separate functional devices connected to a different terminal (multiple switch positions). Operator controlled switches are typically toggle, rocker or potentiometer type devices. They may contain momentary and / or maintained contact arrangements, they may have more than two positions and may incorporate warning, position and / or backlighting. Switches can be as simple as a two position maintained contact rocker type (1) used to turn on or turn off the hazard warning lights (switch also incorporates a warning light which illuminates when the hazard warning position is actuated) or as complex as the multi-position, multifunction, maintained and momentary contact selector type (2) used to operate the parking lights, head lights to include high and low beam control, direction indicators and horn operation. Checking the operation of most of the operator controlled switches can be accomplished by using a multi-meter to test for continuity through the appropriate switch contacts, once the switch connector has been disconnected and the switch has been actuated or de-actuated. Operation or mechanically controlled switches typically use a momentary contact arrangement that is controlled by an actuator. The position of the actuator is controlled by something in the operational environment, such as fluid in a container or fluid, gas or air in a pressurized system or a physical part of the machine like a door, panel or brake rotor or some type of mechanical assembly or linkage apparatus.

1z0o2004112126

1

One of the most common type of mechanically controlled switches is the pressure switch. The pressure switch is actuated by a fluid, gas or air pressure. The signal circuit wiring may be attached as shown (1) to a terminal provided on the device that is internally connected to the stationary contact with the movable contact electrically connected to the metal case (effectively frame ground, used in cases where a conductive, metal, current path exists between the device and the machine frame) or the device may provide terminal connection to both the stationary and movable contacts or the device may provide electrical connection through an integrated or pigtailed connector. Usually the pressure switch employs a diaphragm and spring arrangement that provides a preset amount of opposition to the medium being sensed. The pressure switch opens (or closes) the contacts when the pressure rises (or lowers) past a preset value. Like the operator controlled switches, checking the operation of mechanically controlled switches can be accomplished by using a multi-meter to test for continuity through the switch contacts, once the switch connector has been disconnected and the switch has been actuated or de-actuated. NOTE: A growing number of mechanically controlled devices are incorporating electronics to replace mechanical contacts and to allow for non-contact sensing. These devices are referred to as Sensors rather than Switches and often cannot be continuity tested with a multi-meter.

84522361 15/06/2011

A.30.A / 37

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Overview Resistance devices

1z0o2004112128

1

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 (where equipped) 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. Where applicable, the engine grid heater and heated cab mirrors are other examples of resistance devices designed to convert electricity into heat.

84522361 15/06/2011

A.30.A / 38

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Overview Solenoids NOTE: See also ELECTRICAL POWER SYSTEM - Overview Pulse width modulation (PWM) solenoid valves (A.30.A) for PWM solenoid information.

1z0o2004112133

1

Solenoids 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 MOST COMMON FAULTS that can occur are: •

Short circuit winding: 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.

84522361 15/06/2011

A.30.A / 39

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Overview Pulse width modulation (PWM) solenoid valves

1z0o2004112134

1

Whenever it is necessary to provide proportional control to the solenoid valves, it is much better to use a principle of operation called pulse width modulation (PWM). PWM is a variable DC voltage signal that is used to control the solenoid valves. The voltage signal is pulsed on and off many times a second (at a constant frequency of 500 Hz) at a constant supply voltage of 12 volts. The CM modules contain transistors that are supplied with a constant input voltage which is switched on and off to achieve the variable input range. In this way the control module is able to limit the armature movement, so the hydraulic output flow of the solenoid is proportional to the average DC voltage. The lower voltage also allows the solenoid to operate with less residual magnetism and so the entire circuit will operate smoother. The variable DC voltage signal level is determined by varying the duration of the ON pulse relative to the OFF pulse. The ratio between the ON time and the cycle time is called duty cycle and is stated as a percentage of one complete cycle.

1z0o2004112135

2

Diagrams (1) to (3) show the normal operating range of the PWM valve, and diagram (4), shows the initial 12 volts programming and fill time only. The diagrams in column A show the voltage signal that is sent to the valve, whereas column B shows the relevant spring pressure and column B the reading on a voltmeter connected to the solenoid valve. Diagram (1) shows the OFF position: no signal is directed to the valve, which means no spring pressure in the valve at all and results in a zero voltage reading. Increasing the duty cycle causes some pressure to be made on the circuit (Diagram (2)), which results in a voltmeter reading increase. Diagram (3), shows the maximum signal that is used during the normal activity of the valve: its duty cycle is around 0.5, which results in a spring pressure for the half of its run and in an indication of a 6 volts average DC current. The electrical circuit to the solenoids can be checked by using a digital or analogue DC voltmeter, which will indicate the average voltage readings.

84522361 15/06/2011

A.30.A / 40

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Component identification Fuse Index L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

NOTE: For General Fuse information see Fuse and relay box Fuse - Overview (A.30.A). NOTE: Fuses 1-14 are located in MAIN POWER DISTRIBUTION FUSE BLOCK 1 and can be found on schematic Wiring harness - Electrical schematic frame 04 (A.30.A). Fuses 15-32 are located in ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 and can be found on schematic Wiring harness - Electrical schematic frame 05 (A.30.A). NOTE: For access to fuse blocks see Fuse and relay box - Overview Location and access (A.30.A). For EH machines Component Name HVAC FUSE

Component ID Supplies Power to F-001 HVAC Box

COMPRESSOR FUSE

F-002

F-003 CRANK FUSE REAR WORK LAMPS FUSE F-004 F-005 SIDE LAMPS FUSE

LH TAIL LAMP FUSE UCM BACKUP ALARM FUSE INSTRUMENT CLUSTER FUSE

F-006 F-007

IGNITION FUSE

F-009

RH TAIL LAMP FUSE UNSWITCHED BATTERY FUSE

F-010 F-011

F-008

FRONT WORK LAMPS FUSE F-012 ACCESSORY FUSE

F-013

ACC / BEACON FUSE

F-014

UCM BRAKE LAMPS FUSE F-015 F-016 UCM GRND DRV INTERLOCKS FUSE

HVAC Box HVAC Condenser Fan

Starter Rear Work Lamp Lights Relay #2 Control RH Side Lamp LH Work Lamp LH Tail Lamp UCM Instrument Cluster UCM EGR Telematics Ride Control Horn 2 Speed Switch RH Tail Lamp Instrument Cluster Ignition Switch EGR Seat Switch Operator Restraint Switch LH Side Lamp RH Work Lamp Dome Light Radio HVAC Box Seat Heat Self Level Switch Telematics Accessory Power Outlet Rotating Beacon UCM UCM

84522361 15/06/2011

A.30.A / 41

Information ENVIRONMENT CONTROL Airconditioning system Overview HVAC Electrical (E.40.C) ENVIRONMENT CONTROL Airconditioning system Overview HVAC Electrical (E.40.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name UCM PUMP REV FUSE

UCM PROP AUX FUSE UCM BUCKET FUSE HIGH FLOW / COUPLER FUSE

Component ID Supplies Power to F-017 UCM LH Pump Swash Plate Sensor RH Pump Swash Plate Sensor F-018 UCM F-019 UCM F-020 2nd Aux Hyd Switch Hyd Coupler Switch High Flow Switch F-021 UCM F-022 UCM F-023 Multifunction Attachment Connector F-024 Right Hand Control Handle F-025 UCM F-026 UCM

UCM PUMP FWD FUSE UCM BOOM FUSE FE HOT FUSE FE #1, #2, #3 FUSE UCM INTERLOCKS FUSE UCM UNSWITCHED BATTERY FUSE UCM 2SPD FUSE FE ON / OFF FUSE

F-027 F-028

WIPER / WASHER FUSE FLASHER / BRAKE FUSE LH BOOM FUSE

F-029 F-030 F-031

RH BOOM FUSE

F-032

UCM Electric Auxiliary Hydraulic On / Off Switch Wiper / Washer Switch Flasher Module LH Front Road Lamp LH Rear Position Lamp RH Front Road Lamp RH Rear Position Lamp

84522361 15/06/2011

A.30.A / 42

Information

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Component identification Fuse Index L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

NOTE: For General Fuse information see Fuse and relay box Fuse - Overview (A.30.A). NOTE: Fuses 1-14 are located in MAIN POWER DISTRIBUTION FUSE BLOCK 1 and can be found on schematic Wiring harness - Electrical schematic frame 04 (A.30.A). Fuses 15-21 are located in ACCESSORY POWER DISTRIBUTION and can be found on schematic Wiring harness - Electrical schematic frame 05 (A.30.A). NOTE: For access to fuse blocks see Fuse and relay box - Overview Location and access (A.30.A). For Mech machines Component Name HVAC FUSE

Component ID Supplies Power to F-001 HVAC Box

COMPRESSOR FUSE

F-002

HVAC Box HVAC Condenser Fan

CRANK FUSE SIDE LAMPS FUSE

F-003 F-004

LH TAIL LAMP FUSE RH TAIL LAMP FUSE INSTRUMENT CLUSTER FUSE

F-005 F-006 F-007

IGNITION FUSE

F-008

ACC / BEACON FUSE

F-009

ACCESSORY FUSE

F-010

Starter Lights Relay #2 Control Side Lamp DIA Socket LH Tail Lamp RH Tail Lamp Instrument Cluster Fuel Pump Park Brake Switch Telematics Ride Control Backup Alarm Horn 2 Speed Switch Telematics Accessory Power Outlet Rotating Beacon Dome Light Radio HVAC Box Seat Heat Self Level Switch Instrument Cluster EGR (F5C) Rear Work Lamp LH Side Lamp RH Work Lamp Wiper / Washer Switch Multifunction Attachment Connector Right Hand Control Handle Left Hand Control Handle 2nd Aux Hyd Switch Hyd Coupler Switch High Flow Switch Electric Auxiliary Hydraulic On / Off Switch

UNSWITCHED BATTERY F-011 FUSE REAR WORK LAMPS FUSE F-012 FRONT WORK LAMPS FUSE F-013 WIPER / WASHER FUSE FE HOT FUSE FE #1, #2, #3 FUSE

F-014 F-015 F-016

HIGH FLOW / COUPLER FUSE

F-017

FE ON / OFF FUSE

F-018

84522361 15/06/2011

A.30.A / 43

Information ENVIRONMENT CONTROL Airconditioning system Overview HVAC Electrical (E.40.C) ENVIRONMENT CONTROL Airconditioning system Overview HVAC Electrical (E.40.C)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Component Name FLASHER / BRAKE FUSE LH BOOM FUSE RH BOOM FUSE

Component ID Supplies Power to F-019 Flasher Module Mechanical Brake Pressure Switch F-020 LH Front Road Lamp LH Rear Position Lamp F-021 RH Front Road Lamp RH Rear Position Lamp

84522361 15/06/2011

A.30.A / 44

Information

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box Relay - Overview

1z0o2004112131

1

The relay is an electromagnetic switch that uses a small amount of current to switch a larger amount on and off. Relays are electrically operated switches. They are used to switch a circuit on/off in similar way to a manual switch. When the operator closes a switch, current flows through the relay's control circuit. In this circuit there are windings surrounding an iron core which is fixed in place. Current turns the iron core into an electromagnet. The core then attracts an arm which has a contact point on it. When the point on the arm contacts the stationary point, current flows through the power circuit. Two circuits are connected to the relay: •

A work circuit, which is switched on/off by the relay, and provides the supply for the equipment to be operated, i.e., bulbs, solenoids, etc.;

•

A control circuit, switched on/off by switches, used to operate the relay.

The part of the relay which is connected to the control circuit consists of the winding of an electro-magnet. When the control circuit is switched off, the contacts are kept apart by a return spring. When the control circuit is switched on, a current flows through the coil and a magnetic force is produced. This force, which is stronger than the spring pressure, pulls the contacts of the relay together, causing the work circuit to operate.

1z0o2004112132

2

A switch-relay system has two main advantages over a simple switch: •

The current that flows through the switch is not the same as all the current requested by the equipment to be operated, but usually by a smaller current: this allows the usage of smaller and less expensive switches;

•

The distance from the supply, to the equipment, can be made as short as possible to minimize voltage drop.

84522361 15/06/2011

A.30.A / 45

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

50004701

3

On the relay cover there are 4 or 5 terminal markings: •

3 or 30: input terminal direct from battery positive, normally live.

•

2 or 85: winding output terminal, usually to ground.

•

1 or 86: winding input terminal.

•

4 or 87: output terminal for normally closed contact.

•

5 or 87a: output terminal for normally open contact.

84522361 15/06/2011

A.30.A / 46

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box Fuse - Overview A fuse contains a thin wire, which either melts or vaporizes when too much current flows through it. The resulting open in the circuit stops current flow. The fuse's current rating is normally stamped on the fuse. The purpose of a fuse is to open a circuit when current flow exceeds a certain amount, which is determined by the rating of the fuse. Opening a circuit under high current conditions can save downstream electronic components from damage and prevents overheating, which could cause a fire. An overload can occur as the result of a short circuit or short to ground circuit condition or by connecting equipment that requires current greater than the circuit is designed to carry. There are several types of fuses, but they all consist of a metal conductor which is capable of carrying a specified amount of current. If the specified amount of current is exceeded, the metal conductor will overheat. The overheating causes the metal conductor to melt and break, creating an open circuit condition. NOTE: The following is for illustration purposes only. See your Operator’s Manual for specific Fuse Block location and layout.

50014700

1

The rating of the fuse relates to the current, in amperes, that the fuse can carry continuously. If a fuse fails, replace the fuse with same type and amp rating. Once replaced, if it fails again, the cause for the over-current condition must be investigated and corrected. There are a number of methods that can be used to verify the condition of a fuse. The fuse can be removed from the fuse and relay panel socket and visually inspected to determine if the link has been melted. A continuity test can be performed across the fuse terminals, while the fuse is removed from the fuse and relay panel, if it is not visually apparent that the fuse link is blown. If one of the fuse terminals is connected to battery or switched battery power, a voltage test to ground can be performed from one of the exposed terminals (1) and then the other (1), the battery or switched battery voltage should be seen on both tests (terminals). If battery or switched battery power is NOT connected to either fuse terminal or the power has been disconnected and the fuse is NOT part of a continuous electrical circuit then the fuse can be continuity tested in place in the fuse and relay panel, by checking continuity across the fuse on the two exposed terminals (1). NOTICE: If not certain of exact circuit conditions, performing continuity tests on fuses should be done with the fuse removed from the fuse and relay panel. Performing the test with the fuse still installed in its socket in the fuse and relay panel could provide false indications of the actual fuse condition.

84522361 15/06/2011

A.30.A / 47

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - Overview Location and access Remove the thumbscrews (2) on the cup holder panel to remove the cover to expose the fuses (1). The fuse and relay decal is located at lower left as seen from the operators seat.

93106923

1

93107475

2

87586468

3

To open fuse and relay block 1.

Rotate the box up toward the cab and slide the release tab (1) (red) away from the cover. There are two cover (red) locking tabs. One on top and one on the bottom

2.

Once both of the red locking tabs (1) are in the released position, squeeze the cover on top (2) and bottom to remover cover.

3.

To install the cover (2), align locking tabs and then slide both red locking tabs (1) toward the cover.

84522361 15/06/2011

A.30.A / 48

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

63107475

4

84522361 15/06/2011

A.30.A / 49

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 01 - Connector X-10 to Connector X-13 Connector X-10 - Loader Interface to Chassis (EH)

1

SL57_87382926

Loader Interface to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 510 (WH) 1018 (BL) 511 (WH) 570 (YE) 512 (WH) 1019 (BL) 513 (WH) 571 (YE) 1060 (BK/ WH) 515 (WH) 1020 (BL) 514 (WH) 572 (YE) 236 (PK)

Description Bucket retract signal Bucket return Bucket extend signal Control valve bucket position sensor Loader lower signal Loader return Loader raise signal Control valve loader position sensor Control valve sensor grounds

Frame Wiring harness - Electrical schematic frame 25 (A.30.A)

Proportional aux retract signal Proportional aux return Proportional aux extend signal Control valve aux position sensor Control valve sensor reference voltage

Connector X-101 On Road Light Configuration to Chassis (EH) (Mechanical)

93109185

2

On Road Light Configuration to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 Road lamp signal 702 (VT)

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

84522361 15/06/2011

A.30.A / 50

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-101A On Road Light Configuration Standard to Chassis (EH) (Mechanical)

93109186

3

On Road Light Configuration Standard to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 710 (VT) Road lamp configuration front work lamp control signal

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

Connector X-101B On Road Light Configuration Option to Chassis (EH) (Mechanical)

93109186

4

On Road Light Configuration Option to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 711 (VT) Road lamp configuration boom lamp control signal Connector X-104 Lap Bar Switch to Cab (EH) (Mechanical)

SL57_87382906

5

84522361 15/06/2011

A.30.A / 51

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Lap Bar Switch to Cab (EH) (Mechanical) Description Cavity Circuit ID 1 Lap bar switch unswitched BATT power 316 (RD) 2 314 (YE) Lap bar / Seat belt cluster input

Frame Wiring harness - Electrical schematic frame 20 (A.30.A)

Connector X-107 14-Cavity Receptacle to FE Boom (EH) (Mechanical)

SL57_87696137

6

14-Cavity Receptacle to FE Boom (EH) (Mechanical) Cavity A B C D E F G H J K L M N P

Circuit ID Open 987 (BK) 419 (LG) 418 (GY) 410 (WH) 411 (TN) 416 (VT) 417 (RD) 422 (WH) 420 (OR) 423 (YE) Open Open Open

Description Multifuction attachment ground LH handle multifuction #3 down LH handle multifuction #3 up RH handle multifuction #1 up RH handle multifuction #1 down Handle multifuction #2 up Handle multifuction #2 down Multifunction On/Off attachment signal power Multifunction key power EHF interlock

Frame Wiring harness - Electrical schematic frame 29 (A.30.A) Wiring harness - Electrical schematic frame 24 (A.30.A)

Connector X-108 (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 558 (OR) 554 (WH) 552 (WH) 891 (OR) 770 (OR) 768 (VT) 765 (VT) 892 (WH) 563 (WH) 358 (OR) 424 (VT) 426 (RD) 418 (GY) 419 (LG)

Description

Frame Wiring harness - Electrical schematic frame 33 (A.30.A)

84522361 15/06/2011

A.30.A / 52

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-109 (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 558 (OR) 554 (WH) 552 (WH) 891 (OR) 770 (OR) 768 (VT) 765 (VT) 892 (WH) 563 (WH) 353 (OR) 414 (VT) 415 (RD) 418 (GY) 419 (LG)

Description

Frame Wiring harness - Electrical schematic frame 33 (A.30.A)

Description

Frame Wiring harness - Electrical schematic frame 33 (A.30.A)

Description

Frame Wiring harness - Electrical schematic frame 27 (A.30.A)

Connector X-110 (EH) Cavity Circuit ID 1 856 (WH)

(Mechanical) Cavity Circuit ID 1 129 (OR)

Connector X-11 Interconnect to Chassis Engine (EH) (Mechanical)

SL57_87382911

7

Interconnect to Chassis Engine (EH) (Mechanical) Description Cavity Circuit ID 1 833 (WH) Thermostat to binary pressure switch 2 834 (WH) Binary pressure switch to compressor relay pin 86 3 841 (WH) A/C compressor relay pin 87 power

84522361 15/06/2011

A.30.A / 53

Frame Wiring harness - Electrical schematic frame 17 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-111 Condenser Relay to Cab (EH) (Mechanical)

SL57_87692860

8

Condenser Relay to Cab (EH) (Mechanical) Cavity 30 85 86 87 87a

Circuit ID 839 (RD) 1087 (BK) 840 (WH) 237 (WH) Open

Description Condenser relay pin 30 power Condenser relay ground Condenser relay pin 86 signal HVAC condenser fan power

Frame Wiring harness - Electrical schematic frame 17 (A.30.A)

Connector X-112 (EH) Cavity Circuit ID 1 129 (OR)

Description

Frame Wiring harness - Electrical schematic frame 33 (A.30.A)

Description

Frame Wiring harness - Electrical schematic frame 27 (A.30.A)

Description

Frame Wiring harness - Electrical schematic frame 33 (A.30.A) Wiring harness - Electrical schematic frame 27 (A.30.A)

(Mechanical) Cavity Circuit ID 1 856 (WH)

Connector X-113 (EH) (Mechanical) Cavity Circuit ID D 425 (VT) E 359 (OR) F 427 (RD)

84522361 15/06/2011

A.30.A / 54

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-114 (Mech) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 558 (OR) 454 (WH) 552 (WH) Open 770 (OR) 768 (VT) 765 (VT) 246 (OR) 857 (WH) 353 (OR) 414 (VT) 415 (RD) 418 (GY) 419 (LG)

Description

Frame Wiring harness - Electrical schematic frame 27 (A.30.A)

Description

Frame Wiring harness - Electrical schematic frame 27 (A.30.A)

Description

Frame Wiring harness - Electrical schematic frame 27 (A.30.A)

Connector X-115 (Mech) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 558 (OR) 554 (WH) 552 (WH) Open 770 (OR) 768 (VT) 765 (VT) Open Open 358 (OR) 424 (VT) 426 (RD) 418 (GY) 419 (LG)

Connector X-116 (Mech) Cavity 1 2 3 4 5 6

Circuit ID 352 (OR) 410(WH) 411 (TN) Open 412 (VT) 413 (RD)

84522361 15/06/2011

A.30.A / 55

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-117 (Mech) Cavity 1 2 3 4 5 6 7 8 9 10

Circuit ID 352 (OR) 410(WH) 411 (TN) Open 412 (VT) 413 (RD) Open Open 247(OR) 858 (WH)

Description

Frame Wiring harness - Electrical schematic frame 27 (A.30.A)

Connector X-13 Left Drive Pump Forward to Chassis (EH)

SL57_84122124

9

Left Drive Pump Forward to Chassis (EH) Description Cavity Circuit ID 1 516 (WH) Pump left forward 2 1038 (BL) Pump left forward ground

Frame Wiring harness - Electrical schematic frame 27 (A.30.A)

84522361 15/06/2011

A.30.A / 56

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 02 - Connector X-14 to Connector X-16 Connector X-14 Fuel Level Sender to Chassis (EH) (Mechanical)

1

SL57_87693821

Fuel Level Sender to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 Fuel level sender ground 956 (BK) 2 Fuel level sender 234 (YE)

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

Connector X-15 Accessory Backfeed Diode to Cab (EH) (Mechanical)

cnh_style-24

2

Accessory Backfeed Diode to Cab (EH) (Mechanical) Description Cavity Circuit ID 1 137 (WH) Accessory relay signal 2 153 (WH) Accessory relay signal

Frame Wiring harness - Electrical schematic frame 03 (A.30.A)

Connector X-150 CAN 120 OHM Termination Resistor to Chassis (Mechanical)

DEU_DT06-2S

3

CAN 120 OHM Termination Resistor to Chassis (Mechanical) Cavity Circuit ID 1 502 (YE) CAN HI 2 507 (GN) CAN LO

Description

Frame Wiring harness - Electrical schematic frame 26 (A.30.A)

84522361 15/06/2011

A.30.A / 57

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-155B Right Turn Signal Indicator to Cab (EH) (Mechanical)

SL57_87697629

4

Right Turn Signal Indicator to Cab (EH) (Mechanical) Description Cavity Circuit ID 1 Turn signal indicator RH 771 (VT)

Frame Wiring harness - Electrical schematic frame 14 (A.30.A)

Connector X-156B Left Turn Signal Indicator to Cab (EH) (Mechanical)

SL57_87697629

5

Left Turn Signal Indicator to Cab (EH) (Mechanical) Description Cavity Circuit ID 1 Turn signal indicator LH 772 (YE)

Frame Wiring harness - Electrical schematic frame 14 (A.30.A)

Connector X-157B Turn Signal Indicator to Cab (EH) (Mechanical)

SL57_87697629

6

84522361 15/06/2011

A.30.A / 58

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Turn Signal Indicator to Cab (EH) (Mechanical) Description Cavity Circuit ID 1 Turn signal indicator ground 915 (BK)

Frame Wiring harness - Electrical schematic frame 14 (A.30.A)

Connector X-16 Left Drive Pump Reverse to Chassis (EH)

SL57_84122124

7

Left Drive Pump Reverse to Chassis (EH) Description Cavity Circuit ID 1 517 (WH) Pump left reverse 2 1039 (BL) Pump left reverse ground

Frame Wiring harness - Electrical schematic frame 27 (A.30.A)

84522361 15/06/2011

A.30.A / 59

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 03 - Connector X-161 to Connector X-194 Connector X-161 Mechanical Brake Pressure Switch #1 IN to Chassis (Mechanical)

SL57_87688695

1

Mechanical Brake Pressure Switch #1 IN to Chassis (Mechanical) Description Cavity Circuit ID 1 Brake lamp switches power 720 (RD)

Frame Wiring harness - Electrical schematic frame 05 (A.30.A)

Connector X-162 Mechanical Brake Pressure Switch #1 OUT to Chassis (Mechanical)

SL57_87688695

2

Mechanical Brake Pressure Switch #1 OUT to Chassis (Mechanical) Description Cavity Circuit ID 1 Brake lamp switches 759 (VT)

Frame Wiring harness - Electrical schematic frame 05 (A.30.A)

84522361 15/06/2011

A.30.A / 60

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-163 Mechanical Brake Pressure Switch #2 IN to Chassis (Mechanical)

SL57_87688695

3

Mechanical Brake Pressure Switch #2 IN to Chassis (Mechanical) Description Cavity Circuit ID 1 Brake lamp switches 759 (VT)

Frame Wiring harness - Electrical schematic frame 05 (A.30.A)

Connector X-164 Mechanical Brake Pressure Switch #2 OUT to Chassis (Mechanical)

SL57_87688695

4

Mechanical Brake Pressure Switch #2 OUT to Chassis (Mechanical) Description Cavity Circuit ID 1 Brake lamp signal power 721 (VT)

Frame Wiring harness - Electrical schematic frame 05 (A.30.A)

Connector X-17 Right Drive Pump Forward to Chassis (EH)

SL57_84122124

5

84522361 15/06/2011

A.30.A / 61

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Right Drive Pump Forward to Chassis (EH) Description Cavity Circuit ID 1 519 (WH) Pump right forward 2 1040 (BL) Pump right forward ground

Frame Wiring harness - Electrical schematic frame 27 (A.30.A)

Connector X-178 Beacon Lamp Socket to Cab (EH) (Mechanical)

AMP_480115-1

6

Beacon Lamp Socket to Cab (EH) (Mechanical) Description Cavity Circuit ID A Beacon lamp socket ground 928 (BK) B Beacon switch output 761 (VT)

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

Connector X-18 Right Drive Pump Reverse to Chassis (EH)

SL57_84122124

7

Right Drive Pump Reverse to Chassis (EH) Description Cavity Circuit ID 1 518 (WH) Pump right reverse 2 1041 (BL) Pump right reverse ground

Frame Wiring harness - Electrical schematic frame 27 (A.30.A)

84522361 15/06/2011

A.30.A / 62

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-19 EHF Extend to Chassis (EH)

8

SL57_84122124

EHF Extend to Chassis (EH) Description Cavity Circuit ID 1 431 (WH) EHF extend signal 2 1100 (BL) EHF extend return

Frame Wiring harness - Electrical schematic frame 32 (A.30.A)

Connector X-194 Glow Plug FPT Interface to Chassis (EH) (Mechanical)

93109180

9

Glow Plug FPT Interface to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 Engine preheat relay output 605 (OR)

Frame Wiring harness - Electrical schematic frame 11 (A.30.A)

84522361 15/06/2011

A.30.A / 63

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 04 - Connector X-195 to Connector X-21 Connector X-195 Preheat Fuse to Chassis (EH) (Mechanical)

RING_TERMINAL

1

Preheat Fuse to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 121 (RD) Engine preheat fuse power

Frame Wiring harness - Electrical schematic frame 11 (A.30.A)

Connector X-196 Right-hand Rear Turn Signal to Wire Rear Road Jumper (EH) (Mechanical)

SL57_87688716

2

Right-hand Rear Turn Signal to Wire Rear Road Jumper (EH) (Mechanical) Description Cavity Circuit ID A RH rear turn signal power 736 (VT) B Open C 1002 (BK) RH rear turn signal ground

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

84522361 15/06/2011

A.30.A / 64

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-198 Left-hand Rear Turn Signal to Wire Rear Road Jumper (EH) (Mechanical)

SL57_87688716

3

Left-hand Rear Turn Signal to Wire Rear Road Jumper Description Cavity Circuit ID A LH rear turn signal power 735 (VT) B Open C 1001 (BK) LH rear turn signal ground

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

Connector X-20 Throttle Position Sensor to Chassis (EH)

PAC_12162210

4

Throttle Position Sensor to Chassis (EH) Description Cavity Circuit ID A Throttle position 545 (YE) B 1066 (BK/ Throttle position sensor ground WH) C 211 (PK) Throttle position sensor reference D Open E Open F Open

84522361 15/06/2011

A.30.A / 65

Frame Wiring harness - Electrical schematic frame 25 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-200 Rear Lamp Jumper Interface to Chassis (EH) (Mechanical)

SL57_87382918

5

Rear Lamp Jumper Interface to Chassis (EH) (Mechanical) Cavity 1 2 3 4 5 6

Circuit ID 766 (VT) 763 (VT) 717 (VT) 718 (VT) 721 (VT) 975 (BK)

Description LH rear turn signal power RH rear turn signal power LH rear position lamp RH rear position lamp Brake lamp signal power Rear lamps ground

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

Connector X-201 Rear Lamp Jumper/Chassis Interface to Wire Rear Road Jumper/Light Jumper (EH) (Mechanical)

SL57_87382915

6

Rear Lamp Jumper/Chassis Interface to Wire Rear Road Lamp Jumper (EH) (Mechanical) Cavity 1 2 3 4

Circuit ID 730 (VT) 733 (VT) 731 (VT) 1000 (BK)

Description Rear work lamp power RH tail lamp power LH tail lamp power Rear lamp ground

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

84522361 15/06/2011

A.30.A / 66

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-203 Rear Lamp Jumper Road Lamps/Chassis Interface to Wire Rear Road Jumper (EH) (Mechanical)

SL57_87382919

7

Rear Lamp Jumper Road Lamps/Chassis Interface to Wire Rear Road Jumper (EH) (Mechanical) Cavity 1 2 3 4 5 6

Circuit ID 735 (VT) 736 (VT) 717 (VT) 718 (VT) 737 (VT) 975 (BK)

Description LH rear turn signal power RH rear turn signal power LH rear position lamp RH rear position lamp Brake lamp signal power Rear lamp ground

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

Connector X-21 Bucket Spool Position Sensor to EH Control Valve (EH)

SL47_87694101

8

Bucket Spool Position Sensor to EH Control Valve (EH) Description Cavity Circuit ID 1 206 (PK) Control valve bucket position sensor reference 2 Open 3 1057 (BK/ Control valve bucket position sensor ground WH) 4 570 (YE) Control valve bucket position sensor

84522361 15/06/2011

A.30.A / 67

Frame Wiring harness - Electrical schematic frame 24 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 05 - Connector X-22 to Connector X-232 Connector X-22 Boom Spool Position Sensor to EH Control Valve (EH)

SL57_87694101

1

Boom Spool Position Sensor to EH Control Valve (EH) Description Frame Cavity Circuit ID 1 207 (PK) Control valve loader position sensor reference Wiring harness - Electrical schematic frame 24 (A.30.A) 2 Open 3 1058 (BK/ Control valve loader position sensor ground WH) 4 571 (YE) Control valve loader position sensor Connector X-228 Left-hand Boom Road Lamp to Wire FE Boom (EH) (Mech)

SL57_87694112

2

Left-hand Boom Road Lamp to FE Road Boom (EH) (Mech) Cavity 1 2 3 4 5 6

Circuit ID 979 (BK) 742 (VT) Open 741 (VT) 767 (VT) Open

Description LH boom lamps ground LH boom lamp low beam

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

LH lamp position LH boom turn signal power

84522361 15/06/2011

A.30.A / 68

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-229 Right hand Boom Road Lamp to FE Road Boom (EH) (Mech) Cavity 1 2 3 4 5

Circuit ID 960 (BK) 540 (VT) Open 539 (VT) 764 (VT)

Description

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

Connector X-23 Auxiliary Spool Position Sensor to EH Control Valve (EH)

SL57_87694101

3

Auxiliary Spool Position Sensor to EH Control Valve (EH) Description Cavity Circuit ID 1 208 (PK) Control valve aux position sensor reference 2 Open 3 1059 (BK/ Control valve aux position sensor ground WH) 4 572 (YE) Control valve aux position sensor

Frame Wiring harness - Electrical schematic frame 24 (A.30.A)

Connector X-230 Left-hand Boom Lights Interconnect to Chassis (EH) (Mechanical)

SL57_87697724

4

Left-hand Boom Lights Interconnect to Chassis (EH) (Mechanical) Cavity A B C D

Description Circuit ID LH boom road lamps signal 712 (VT) LH boom turn signal power 767 (VT) Open LH boom lamps ground 979 (BK)

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

84522361 15/06/2011

A.30.A / 69

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-231 Right-hand Boom Lights Interconnect to Chassis (EH) (Mechanical)

SL57_87697724

5

Right-hand Boom Lights Interconnect to Chassis (EH) (Mechanical) Cavity A B C D

Description Circuit ID RH boom road lamps signal 713 (VT) RH boom turn signal power 764 (VT) Open RH boom lamps ground 980 (BK)

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

Connector X-232 Left-hand Boom Lights Interconnect to FE Road Boom (EH) (Mechanical)

SL57_87697723

6

Left-hand Boom Lights Interconnect to FE Road Boom (EH) (Mechanical) Cavity A B C D

Description Circuit ID LH boom road lamps signal 712 (VT) LH boom turn signal power 767 (VT) Open LH boom lamps ground 979 (BK)

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

84522361 15/06/2011

A.30.A / 70

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 06 - Connector X-233 to Connector X-275 Connector X-233 (EH) (Mech) Cavity A B C D

Circuit ID 713 (VT) 764 (VT) Open 980 (BK)

Description

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

Connector X-24 Proportional Auxiliary Valve Extend to EH Control Valve (EH)

SL57_87695582

1

Proportional Auxiliary Valve Extend to EH Control Valve (EH) Description Cavity Circuit ID 1 514 (WH) Proportional aux extend signal 2 1083 (BL) Proportional aux extend return

Frame Wiring harness - Electrical schematic frame 24 (A.30.A)

Connector X-24 Proportional Auxiliary Valve Extend to EH Control Valve (EH)

SL57_87695582

2

Bucket Valve Retract to EH Control Valve (EH) Description Cavity Circuit ID 1 510 (WH) Bucket retract signal 2 1078 (BL) Bucket retract return

Frame Wiring harness - Electrical schematic frame 24 (A.30.A)

84522361 15/06/2011

A.30.A / 71

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-252 Temp Control Switch to Cab (EH) (Mechanical)

SL57_87714670

3

Temp Control Switch to Cab (EH) (Mechanical) Description Cavity Circuit ID 1 912 (BK) HVAC temperature switch ground 2 824 (YE) HVAC temperature control signal 3 823 (PK) HVAC temperature switch power

Frame Wiring harness - Electrical schematic frame 17 (A.30.A)

Connector X-26 Bucket Valve Extend to EH Control Valve (EH)

SL57_87695582

4

Bucket Valve Extend to EH Control Valve (EH) Description Cavity Circuit ID 1 511 (WH) Bucket extend signal 2 1079 (BL) Bucket extend return

Frame Wiring harness - Electrical schematic frame 24 (A.30.A)

Connector X-27 Loader Valve Retract to EH Control Valve (EH)

SL57_87695582

5

84522361 15/06/2011

A.30.A / 72

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Loader Valve Retract to EH Control Valve (EH) Description Cavity Circuit ID 1 512 (WH) Loader lower signal 2 1080 (BL) Loader lower return

Frame Wiring harness - Electrical schematic frame 24 (A.30.A)

Connector X-270 Blower Fan Switch to Cab (EH) (Mechanical)

754C-3

6

Blower Fan Switch to Cab (EH) (Mechanical) Cavity 1 2 3 4 5

Circuit ID 825 (OR) 821 (OR) 828 (WH) 827 (WH) 826 (WH)

Description HVAC clutch Blower switch power HVAC fan low HVAC fan medium HVAC fan high

Frame Wiring harness - Electrical schematic frame 17 (A.30.A)

Connector X-271 Water Valve to Chassis (EH) (Mechanical)

SL57_87694714

7

Water Valve to Chassis (EH) (Mechanical) Cavity A B C D E F

Description Circuit ID 822 (OR) HVAC water valve power Open 1013 (BK) Water valve ground 824 (YE) HVAC temperature control signal Open Open

84522361 15/06/2011

A.30.A / 73

Frame Wiring harness - Electrical schematic frame 17 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-275 A/C Switch to Cab (EH) (Mechanical)

93109181

8

A/C Switch to Cab (EH) (Mechanical) Description Cavity Circuit ID A 825 (OR) HVAC clutch B 913 (BK) HVAC compressor clutch switch ground C 829 (WH) HVAC compressor switch

84522361 15/06/2011

A.30.A / 74

Frame Wiring harness - Electrical schematic frame 17 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 07 - Connector X-28 to Connector X-303 Connector X-28 Loader Valve Extend to EH Control Valve (EH)

1

SL57_87695582

Loader Valve Extend to EH Control Valve (EH) Description Cavity Circuit ID 1 513 (WH) Loader raise signal 2 1081 (BL) Loader raise return

Frame Wiring harness - Electrical schematic frame 24 (A.30.A)

Connector X-29 Proportional Auxiliary Valve Retract to EH Control Valve (EH)

2

SL57_87695582

Proportional Auxiliary Valve Retract to EH Control Valve (EH) Description Cavity Circuit ID 1 515 (WH) Proportional aux retract signal 2 1082 (BL) Proportional aux retract return

Frame Wiring harness - Electrical schematic frame 24 (A.30.A)

Connector X-298 EH UCM Wakeup Diode to Chassis (EH)

cnh_style-24

3

EH UCM Wakeup Diode to Chassis (EH) Description Cavity Circuit ID A 334 (OR) Main power relay UCM wakeup B 333 (YE) UCM wakeup diode out 84522361 15/06/2011

A.30.A / 75

Frame Wiring harness - Electrical schematic frame 20 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-2SPD 2 Speed Valve Solenoid to Chassis (EH Medium and Large frame) (Mechanical Medium and Large frame)

SL57_87693821

4

2 Speed Valve Solenoid to Chassis (EH Medium and Large frame) (Mechanical Medium and Large frame) Description Cavity Circuit ID A 564 (WH) 2 speed valve solenoid signal B 2 speed valve ground 953 (BK)

Frame Wiring harness - Electrical schematic frame 07 (A.30.A)

Connector X-30 Right-hand Lamp Jumper Interface to Cab (EH) (Mechanical)

SL57_87694154

5

Right-hand Lamp Jumper Interface to Cab (EH) (Mechanical) Cavity 1 2 3 4

Circuit ID 798 (VT) 793 (VT) 779 (VT) 926 (BK)

RH RH RH RH

Description work lamp power side lamp power cab turn signal power cab lamps ground

Frame Wiring harness - Electrical schematic frame 16 (A.30.A)

84522361 15/06/2011

A.30.A / 76

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-300 Hydraulic Coupler Switch to Cab (EH) (Mechanical)

SL57_84159859

6

Hydraulic Coupler Switch to Cab (EH) (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10

Description Circuit ID Open Hydraulic coupler switch in 751 (OR) 752 (WH) Hydraulic coupler signal Open Open Open Open Open Hydraulic coupler switch indicator ground 918 (BK) Open

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

Connector X-301 Beacon Lamp Switch to Cab (EH) (Mechanical)

SL57_87697780

7

Beacon Lamp Switch to Cab (EH) (Mechanical) Cavity A B C D E F

Description Circuit ID Beacon switch indicator ground 919 (BK) Open Open Beacon switch output 761 (VT) Beacon power 796 (VT) Open

84522361 15/06/2011

A.30.A / 77

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-302 Hazard Lamp Switch to Cab (EH) (Mechanical)

SL57_84159858

8

Hazard Lamp Switch to Cab (EH) (Mechanical) Cavity A B C D E F

Circuit ID 776 (VT) 784 (OR) 920 (BK) Open 785 (OR) 778 (VT)

Description Hazard switch LH turn signal output LH hazard flasher power in Hazard switch indicator ground

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

RH hazard flasher power in Hazard switch RH turn signal output

Connector X-303 Hi Flow Switch to Cab (EH) (Mechanical)

SL57_87693037

9

Hi Flow Switch to Cab (EH) Cavity A B C D E

Circuit ID 755 (WH) 753 (OR) 750 (WH) Open 921 (BK)

Description High performance high flow signal High flow switch in Standard high flow signal

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

High flow switch indicator ground

Hi Flow Switch to Cab (Mechanical) Cavity A B C D E

Description Circuit ID Open 753 (OR) High flow switch in 750 (WH) Standard high flow signal Open 921 (BK) High flow switch indicator ground

84522361 15/06/2011

A.30.A / 78

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 08 - Connector X-304 to Connector X-317 Connector X-304 Auxiliary ON/OFF Switch to Cab (EH) (Mechanical)

SL57_87697780

1

Auxiliary ON/OFF Switch to Cab (EH) (Mechanical) Cavity A B C D E F

Description Circuit ID 923 (BK) Aux elec On/Off switch indicator ground Open Open 856 (WH) Aux elec On/Off switch signal 129 (OR) Aux elec On/Off switch in Open

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

Connector X-306 Loader Lockout Switch to Cab (EH) (Mechanical)

SL57_87693037

2

Loader Lockout Switch to Cab (EH) Cavity A B C D E

Circuit ID 312 (YE) 311 (OR) 398 (YE) Open 924 (BK)

Description Loader lock switch N.C. output (valve on) Loader lockout switch in Loader lockout switch N.O. output (valve off) Loader lock switch indicator ground

84522361 15/06/2011

A.30.A / 79

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Loader Lockout Switch to Cab (Mechanical) Cavity A B C D E

Description Circuit ID 312 (WH) Loader lock switch out 311 (WH) Loader lockout switch in Open Open Loader lock switch indicator ground 924 (BK)

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

Connector X-31 Left-hand Lamp Jumper Interface to Cab (EH) (Mechanical)

SL57_87694154

3

Left-hand Lamp Jumper Interface to Cab (EH) (Mechanical) Cavity 1 2 3 4

Circuit ID 799 (VT) 794 (VT) 773 (VT) 927 (BK)

Description Left hand work lamp power Left hand side lamp power Left hand cab turn signal power Left hand cab lamps ground

Frame Wiring harness - Electrical schematic frame 16 (A.30.A)

Connector X-310 Two Speed Indicator to Cab (EH) (Mechanical)

SL57_84159859

4

84522361 15/06/2011

A.30.A / 80

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Two Speed Indicator to Cab (EH) (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10

Description Circuit ID Open Open Open Open Open Open 565 (VT) 2 Speed indicator Open 917 (BK) 2 Speed indicator ground Open

Frame Wiring harness - Electrical schematic frame 14 (A.30.A)

Connector X-311 Lamp Selector Switch to Cab (EH) (Mechanical)

754C-3

5

Lamp Selector Switch to Cab (EH) (Mechanical) Cavity 1 2 3 4 5

Circuit ID Open 123 (OR) 790 (VT) 791 (VT) 792 (VT)

Description Lamp switch power Lamp switch work lamp signal Lamp switch road lamp signal Lamp switch work and side lamp signal

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

Connector X-316 Ignition Backfeed Diode to Chassis (EH) (Mechanical)

cnh_style-24

6

Ignition Backfeed Diode to Chassis (EH) (Mechanical) Description Cavity Circuit ID A Main power relay signal 133 (OR) B Main power relay signal 144 (OR)

Frame Wiring harness - Electrical schematic frame 04 (A.30.A)

84522361 15/06/2011

A.30.A / 81

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-317 Self Level Switch to Cab (EH) (Mechanical)

SL57_87693037

7

Self Level Switch to Cab (EH) (Mechanical) Cavity A B C D E

Description Circuit ID 404 (WH) Self level switch output power 405 (OR) Self level switch power Open Open 922 (BK) Self level switch indicator ground

84522361 15/06/2011

A.30.A / 82

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 09 - Connector X-318 to Connector X-332 Connector X-318 Self Level Valve to Chassis (EH) (Mechanical)

SL57_87695582

1

Self Level Valve to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 404 (WH) Self level switch output power 2 949 (BK) Self level ground

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

Connector X-323 Multifunction Interconnect to Chassis (EH) (Mechanical)

SL57_87382922

2

Multifunction Interconnect to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10

Circuit ID 419 (LG) 418 (GY) 410 (WH) 411 (TN) 416 (VT) 417 (RD) 982 (BK) 856 (WH) 420 (OR) 423 (YE)

Description LH handle multifunction #3 down LH handle multifunction #3 up RH handle multifunction #1 up RH handle multifunction #1 down Handle multifunction #2 up Handle multifunction #2 down Multifunctional ground Aux elec on/off switch signal Multifunction key power EHF interlock

84522361 15/06/2011

A.30.A / 83

Frame Wiring harness - Electrical schematic frame 29 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Multifunction Interconnect to Chassis (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10

Circuit ID 419 (LG) 418 (GY) 410 (WH) 411 (TN) 416 (VT) 417 (RD) 982 (BK) 856 (WH) 420 (OR) Open

Description LH handle multifunction #3 down LH handle multifunction #3 up RH handle multifunction #1 up RH handle multifunction #1 down Handle multifunction #2 up Handle multifunction #2 down Multifunctional ground Aux elec on/off switch signal Multifunction key power

Frame Wiring harness - Electrical schematic frame 24 (A.30.A)

Connector X-323A to FE Boom (EH) (Mechanical) FE Boom (EH) Cavity 1 2 3 4 5 6 7 8 9 10

Circuit ID 419 (LG) 418 (GY) 410 (WH) 411 (TN) 416 (VT) 417 (RD) 982 (BK) 856 (WH) 420 (OR) 423 (YE)

Description LH handle multifunction #3 down LH handle multifunction #3 up RH handle multifunction #1 up RH handle multifunction #1 down Handle multifunction #2 up Handle multifunction #2 down Multifunction ground Aux elec on/off switch signal Multifunction key power EHF interlock

Frame Wiring harness - Electrical schematic frame 29 (A.30.A)

FE Boom (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10

Circuit ID 419 (LG) 418 (GY) 410 (WH) 411 (TN) 416 (VT) 417 (RD) 982 (BK) 856 (WH) 420 (OR) Open

Description LH handle multifunction #3 down LH handle multifunction #3 up RH handle multifunction #1 up RH handle multifunction #1 down Handle multifunction #2 up Handle multifunction #2 down Multifunction ground Aux elec on/off switch signal Multifunction key power

Frame Wiring harness - Electrical schematic frame 24 (A.30.A)

Connector X-330 Right Speaker to Cab (EH) (Mechanical)

SL57_87697629

3

84522361 15/06/2011

A.30.A / 84

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Right Speaker to Cab (EH) (Mechanical) Description Cavity Circuit ID 1 451 (WH) Right speaker (+)

Frame Wiring harness - Electrical schematic frame 21 (A.30.A)

Connector X-331 Right Speaker to Cab (EH) (Mechanical)

SL57_87697629

4

Right Speaker to Cab (EH) (Mechanical) Description Cavity Circuit ID 1 450 (BL) Right speaker (-)

Frame Wiring harness - Electrical schematic frame 21 (A.30.A)

Connector X-332 Left Speaker to Cab (EH) (Mechanical)

SL57_87697629

5

Left Speaker to Cab (EH) (Mechanical) Description Cavity Circuit ID 1 453 (WH) Left speaker (+)

Frame Wiring harness - Electrical schematic frame 21 (A.30.A)

84522361 15/06/2011

A.30.A / 85

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 10 - Connector X-333 to Connector X-35 Connector X-333 Left Speaker to Cab (EH) (Mechanical)

SL57_87697629

1

Left Speaker to Cab (EH) (Mechanical) Description Cavity Circuit ID 1 452 (BL) Left speaker (-)

Frame Wiring harness - Electrical schematic frame 21 (A.30.A)

Connector X-335 Radio to Cab (EH) (Mechanical)

SL57_84257494

2

Radio to Cab (EH) (Mechanical) Cavity 1 2 3 4 5 6 7 8 9

Circuit ID Open 452 (BL) Open 451 (WH) 450 (BL) 453 (WH) 934 (BK) Open 130 (OR)

Description

Frame Wiring harness - Electrical schematic frame 21 (A.30.A)

Left speaker (-) Right speaker (+) Right speaker (-) Left speaker (+) Radio ground Radio power

Connector X-33A (Mechanical) Cavity Circuit ID A 729 (VT) B 997 (BK)

Description

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

84522361 15/06/2011

A.30.A / 86

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-34 Left-hand Rear Work Lamp to Rear Road Jumper/Lamp Jumper (EH)

SL57_87695582

3

Left-hand Rear Work Lamp to Rear Road Jumper/Lamp Jumper (EH) Description Cavity Circuit ID 1 LH rear work lamp power 728 (VT) 2 LH rear work lamp ground 996 (BK)

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

Connector X-341 LH Rear Strobe Lamp to Strobe (EH) (Mechanical)

SL57_87694153

4

LH Rear Strobe Lamp to Strobe (EH) (Mechanical) Cavity 1 2 3 4

Circuit ID LH rear strobe 758 (VT) 1007 (BK) LH rear strobe Open LH rear strobe 683 (PK)

Description power ground

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

sync

Connector X-342 RH Rear Strobe Lamp to Strobe (EH) (Mechanical)

SL57_87694153

5

84522361 15/06/2011

A.30.A / 87

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

RH Rear Strobe Lamp to Strobe (EH) (Mechanical) Cavity 1 2 3 4

Circuit ID RH rear strobe 757 (VT) 1006 (BK) RH rear strobe Open RH rear strobe 682 (PK)

Description power ground

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

sync

Connector X-343 RH Front Strobe Light to Strobe (EH) (Mechanical)

SL57_87694153

6

RH Front Strobe Light to Strobe (EH) (Mechanical) Cavity 1 2 3 4

Circuit ID 739 (VT) RH front strobe 1004 (BK) RH front strobe Open 680 (PK) RH front strobe

Description power ground

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

sync

Connector X-344 LH Front Strobe Lamp to Strobe (EH) (Mechanical)

SL57_87694153

7

LH Front Strobe Lamp to Strobe (EH) (Mechanical) Cavity 1 2 3 4

Circuit ID 740 (VT) LH front strobe 1005 (BK) LH front strobe Open 681 (PK) LH front strobe

Description power ground

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

sync

84522361 15/06/2011

A.30.A / 88

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-35 Right-hand Rear Work Light to Rear Road Jumper/Lamp Jumper (EH)

SL57_87695582

8

Right-hand Rear Work Light to Rear Road Jumper/Lamp Jumper (EH) Description Cavity Circuit ID 1 RH rear work lamp power 729 (VT) 2 RH rear work lamp ground 997 (BK)

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

84522361 15/06/2011

A.30.A / 89

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 11 - Connector X-365 to Connector X-406 Connector X-365 Park Brake Switch to Cab (EH) (Mechanical)

SL57_84159859

1

Park Brake Switch to Cab (EH) Cavity 1 2 3 4 5 6 7 8 9 10

Description Circuit ID Open RH console park brake sw 194 (OR) RH console park brake sw out 306 (YE) Open Open Open Open Open Open Open

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

Park Brake Switch to Cab (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10

Description Circuit ID Open RH console park brake switch 305 (YE) RH console park brake sw out 306 (YE) Open Open Open Open Open Open Open

84522361 15/06/2011

A.30.A / 90

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-37 Left-hand Rear Position Lamp to Rear Road Jumper/Lamp Jumper (EH) (Mechanical)

SL57_87688716

2

Left-hand Rear Position Lamp to Rear Road Jumper (EH) (Mechanical) Description Cavity Circuit ID A LH tail lamp power 731 (VT) B 998 (BK) LH stop / tail lights ground LH stop lamp power C 732 (VT)

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

Connector X-38 RH Rear Work Lamp to Wire Rear Road Jumper/Lamp Jumper (Mechanical)

SL57_82003123

3

RH Rear Work Lamp to Wire Rear Road Jumper/Lamp Jumper (Mechanical) Description Cavity Circuit ID A RH rear work lamp power 729 (VT) B RH rear work lamp ground 997 (BK)

Frame

Connector X-39 LH Rear Position Lamp to Wire Rear Road Jumper (EH) (Mechanical)

SL57_87688716

4

84522361 15/06/2011

A.30.A / 91

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

LH Rear Position Lamp to Wire Rear Road Jumper (EH) (Mechanical) Description Cavity Circuit ID A LH stop lamp power 732 (VT) B LH tail lamp power 897 (VT) C 1091 (BK) LH stop/tail lamps ground

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

Connector X-40 EHF Retract to Chassis (EH)

SL57_84122124

5

EHF Retract to Chassis (EH) Description Cavity Circuit ID 1 430 (WH) EHF retract signal 2 1101 (BL) EHF retract return

Frame Wiring harness - Electrical schematic frame 32 (A.30.A)

Connector X-401 (EH) Cavity Circuit ID A 856 (WH) B 129 (OR)

Description

Frame Wiring harness - Electrical schematic frame 33 (A.30.A)

Connector X-402 RH Handle Interconnect Park Brake/Ride Control to Chassis (Mechanical)

SL57_87382922

6

Connector X-402 RH Handle Interconnect Park Brake/Ride Control to Chassis (Mechanical) Cavity 1 2 3 4 5 6

Circuit ID 324 (OR) 307 (YE) 832 (OR) 831 (WH) Open Open

Description RH grip park brake switch power RH grip park brake switch output Ride control valve solenoid switch power Ride control valve solenoid signal

84522361 15/06/2011

A.30.A / 92

Frame Wiring harness - Electrical schematic frame 07 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Description Frame Cavity Circuit ID 7 Open Wiring harness - Electrical schematic 8 EH aux proportional switch signal output 699 (PK) frame 23 (A.30.A) 9 1010 (BK/ EH aux proportional switch ground WH) 10 331 (OR) EH aux proportional switch reference voltage Connector X-403 Right-hand Handle Interconnect Female/Proportional Auxiliary/Float to Cab (EH)

SL57_87382928

7

Right-hand Handle Interconnect Female/Proportional Auxiliary/Float to Cab (EH) Cavity Circuit ID 1 213 (PK) 2 547 (YE) 3 1052 (BK/ WH) 4 Open 5 352 (OR) 6 410 (WH) 7 411 (TN) 8 412 (VT) 9 413 (RD) 10 214 (PK) 11 546 (YE) 12 1053 (BKWH) 13 406 (OR) 14 531 (YE)

Description Proportional aux switch #2 reference Proportional aux switch output signal #1 Proportional aux switch #2 ground

Frame Wiring harness - Electrical schematic frame 19 (A.30.A)

RH handle multifunction #1 / #2 power RH handle multifunction #1 up RH handle multifunction #1 down RH handle multifunction #2 up RH handle multifunction #2 down Proportional aux switch #1 reference Proportional aux switch output signal #2 Proportional aux switch #1 ground

Wiring harness - Electrical schematic frame 07 (A.30.A)

Wiring harness - Electrical schematic frame 19 (A.30.A)

Float switch input voltage Loader float switch input

Connector X-404 RH Handle Interconnect Multifunction #1/#2 to Chassis (Mechanical)

SL57_87382918

8

84522361 15/06/2011

A.30.A / 93

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

RH Handle Interconnect Multifunction #1/#2 to Chassis (Mechanical) Cavity 1 2 3 4 5 6

Circuit ID 352 (OR) 410 (WH) 411 (TN) Open 412 (VT) 413 (RD)

Description RH handle multifunctional #1/2 power RH handle multifunctional #1 up RH handle multifunctional #1 down

Frame Wiring harness - Electrical schematic frame 07 (A.30.A)

RH handle multifunctional #2 up RH handle multifunctional #2 down

Connector X-405 LH Handle Interconnect Horn/Two Speed to Chassis (Mechanical)

SL57_87697723

9

Connector X-405 LH Handle Interconnect Horn/Two Speed to Chassis (Mechanical) Cavity A B C D

Description Circuit ID 891 (OR) LH grip horn/2 speed switch power 892 (WH) Horn power signal Open 563 (WH) 2 speed switch output signal

Frame Wiring harness - Electrical schematic frame 07 (A.30.A)

Connector X-406 Right-hand Handle Interconnect Park Brake/Ride Control to Cab (EH)

SL57_87697723

10

Right-hand Handle Interconnect Park Brake/Ride Control to Cab (EH) Cavity A B C D

Circuit ID 324 (OR) 307 (YE) 832 (OR) 831 (WH)

Description RH grip park brake switch power RH grip park brake sw output Ride control valve solenoid switch power Ride control valve solenoid signal

84522361 15/06/2011

A.30.A / 94

Frame Wiring harness - Electrical schematic frame 07 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 12 - Connector X-407 to Connector X-430 Connector X-407 LH Handle Interconnect 2nd Auxiliary/Turn Signal to Chassis Options (Mechanical)

SL57_87382929

1

LH Handle Interconnect 2nd Auxiliary/Turn Signal to Chassis Options (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 558 (OR) 554 (WH) 552 (WH) Open 770 (OR) 768 (VT) 765 (VT) Open Open 353 (OR) 414 (VT) 415 (RD) 418 (GY) 419 (LG)

Description 2nd aux switch power 2nd aux extend switch output 2nd aux retract signal power

Frame Wiring harness - Electrical schematic frame 07 (A.30.A)

LH grip flasher power LH grip LH turn signal output signal LH grip RH turn signal output signal

LH handle multifunction #2/3 power LH handle multifunction #2 up LH handle multifunction #2 down LH handle multifunction #3 up LH handle multifunction #3 down

Connector X-408 Left-hand Interconnect to Cab (EH)

SL57_87382929

2

84522361 15/06/2011

A.30.A / 95

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Left-hand Interconnect to Cab (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 558 (OR) 554 (WH) 552 (WH) 891 (OR) 770 (OR) 768 (VT) 765 (VT) 892 (WH) 563 (WH) 353 (OR) 414 (VT) 415 (RD) 418 (GY) 419 (LG)

Description 2nd aux switch power 2nd aux extend switch output 2nd aux retract signal power LH grip horn / 2 speed sw power LH grip flasher power LH grip LH turn signal output signal LH grip RH turn signal output signal Horn power signal 2 speed switch output signal LH handle multifunction #2 / #3 power LH handle multifunction #2 up LH handle multifunction #2 down LH handle multifunction #3 up LH handle multifunction #3 down

Frame Wiring harness - Electrical schematic frame 07 (A.30.A)

Connector X-410 Loader Lock/Chassis Harness Interconnect to Chassis (Mechanical)

SL57_87695584

3

Loader Lock/Chassis Harness Interconnect to Chassis (Mechanical) Description Cavity Circuit ID 1 311 (WH) Loader lockout switch in 2 Hydraulic loader interlock ground 969 (BK)

Frame Wiring harness - Electrical schematic frame 15 (A.30.A)

Connector X-411 Flasher Module to Chassis (EH) (Mechanical)

SL57_87692860

4

84522361 15/06/2011

A.30.A / 96

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Flasher Module to Chassis (EH) Cavity 30 85 86 87 87A

Description Circuit ID 156 (RD) Flasher/brake power Flasher ground 981 (BK) Open Open 769 (OR) Flasher module output/power

Frame Wiring harness - Electrical schematic frame 16 (A.30.A)

Flasher Module to Chassis (Mechanical) Cavity 30 85 86 87 87A

Description Circuit ID 155 (RD) Flasher/brake power Flasher ground 981 (BK) Open Open 769 (OR) Flasher module output/power

Frame Wiring harness - Electrical schematic frame 16 (A.30.A)

Connector X-412 Loader Lock Port Lock Valve Connection to Chassis (Mechanical)

SL57_87695582

5

Loader Lock Port Lock Valve Connection to Chassis (Mechanical) Description Cavity Circuit ID 1 312 (WH) Loader lock switch out 2 Hydraulic loader interlock ground 969 (BK)

Frame Wiring harness - Electrical schematic frame 15 (A.30.A)

Connector X-42 Mechanical Back Up Switch #1 to Chassis (Mechanical)

SL57_87695584

6

Mechanical Back Up Switch #1 to Chassis (Mechanical) Description Cavity Circuit ID 1 893 (WH) Backup alarm switch power 2 894 (WH) Backup alarm switch to switch 84522361 15/06/2011

A.30.A / 97

Frame Wiring harness - Electrical schematic frame 04 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-43 Mechanical Back Up Switch #2 to Chassis (Mechanical)

7

SL57_87695584

Mechanical Back Up Switch #2 to Chassis (Mechanical) Description Cavity Circuit ID 1 894 (WH) Backup alarm switch to switch 2 895 (WH) Backup alarm signal

Frame Wiring harness - Electrical schematic frame 04 (A.30.A)

Connector X-430 EH Auxiliary Power Controller to Chassis (Mechanical)

DT06-08SA

8

Mechanical Back Up Switch #2 to Chassis (Mechanical) Cavity Circuit ID 1 319 (OR) 2 901 (BK/ WH) 3 889 (WH) 4 890 (WH) 5 1009 (BL) 6 699 (PK) 7 1010 (BK/ WH) 8 331 (OR)

Description

Frame Wiring harness - Electrical schematic frame 19 (A.30.A)

EH aux power PWM controller ground EH aux extend signal EH aux retract signal EH aux valve signal return EH aux proportional switch signal output EH aux proportional switch ground EH aux proportional switch reference voltage

84522361 15/06/2011

A.30.A / 98

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 13 - Connector X-432 to Connector X-502 Connector X-432 Proportional Auxiliary Valve Retract to Chassis (Mechanical)

SL57_87695582

1

Proportional Auxiliary Valve Retract to Chassis (Mechanical) Description Cavity Circuit ID 1 890 (WH) EH aux retract signal 2 EH aux retract ground 914 (BL)

Frame Wiring harness - Electrical schematic frame 19 (A.30.A)

Connector X-433 Proportional Auxiliary Valve Extend to Chassis (Mechanical)

SL57_87695582

2

Proportional Auxiliary Valve Extend to Chassis (Mechanical) Description Cavity Circuit ID 1 889 (WH) EH aux extend signal 2 EH aux extend ground 911 (BL)

Frame Wiring harness - Electrical schematic frame 19 (A.30.A)

84522361 15/06/2011

A.30.A / 99

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-44 Right-hand Rear Position Lamp to Wire Rear Road Jumper/Lamp Jumper (EH) (Mechanical)

SL57_87688716

3

Right-hand Rear Position Lamp to Wire Rear Road Jumper (EH) (Mechanical) Description Cavity Circuit ID A RH tail lamp power 733 (VT) B RH stop lamp power 734 (VT) C 999 (BK) RH stop /tail lamps ground

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

Connector X-49 RH Rear Position Lamp to Wire Rear Road Jumper (EH) (Mechanical)

SL57_87688716

4

RH Rear Position Lamp to Wire Rear Road Jumper (EH) (Mechanical) Description Cavity Circuit ID A RH stop lamp power 734 (VT) B RH rear position lamp 718 (VT) C 1092 (BK) RH stop / tail lamps ground

Frame Wiring harness - Electrical schematic frame 18 (A.30.A)

Connector X-5 Alternator to Engine (ISM and F5C)

SL57_84165069

5

84522361 15/06/2011

A.30.A / 100

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Alternator to Engine (ISM and F5C) Description Cavity Circuit ID 1 Alternator lamp telematics engine on 244 (YE) 2 Alternator excite 121 (OR) 3 Engine RPM signal 124 (YE)

Frame Wiring harness - Electrical schematic frame 12 (A.30.A) Wiring harness - Electrical schematic frame 13 (A.30.A)

Connector X-502 Door Wiper Motor to Cab (EH) (Mechanical)

SL57_87697724

6

Door Wiper Motor to Cab (EH) (Mechanical) Cavity A B C D

Circuit ID 227 (WH) 929 (BK) 231 (OR) 220 (YE)

Door Door Door Door

Description wiper motor signal wiper motor ground wiper motor park switch bypass

84522361 15/06/2011

A.30.A / 101

Frame Wiring harness - Electrical schematic frame 09 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 14 - Connector X-502A to Connector X-510 Connector X-502A Rear Window Wiper Motor to Cab (EH) (Mechanical)

SL57_87693712

1

Rear Window Wiper Motor to Cab (EH) (Mechanical) Description Cavity Circuit ID A 228 (WH) Rear window wiper motor signal B Rear window wiper motor ground 930 (BK) Rear window wiper motor park C 232 (OR)

Frame Wiring harness - Electrical schematic frame 09 (A.30.A)

Connector X-503 Wiper/Washer Switch to Cab (EH) (Mechanical)

SL57_87716755

2

Wiper/Washer Switch to Cab (EH) (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10

Circuit ID 931 (BK) 225 (WH) 229 (OR) Open 224 (WH) 230 OR) 226 (VT) 932 (BK) Open Open

Description Frame Wiring harness - Electrical schematic Wiper/washer sw ground Wiper motor and indicator lamp power output frame 09 (A.30.A) Wiper/washer sw motor power in Washer pump signal Wiper/washer sw motor pump in Wiper/washer lamp signal Wiper/washer sw indicator ground

84522361 15/06/2011

A.30.A / 102

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-504 Engine Coolant Temperature Sender (F5C)

SL57_84159852

3

Engine Coolant Temperature Sender (F5C) Description Cavity Circuit ID 1 257 (YE) Coolant temperature sensor

Frame Wiring harness - Electrical schematic frame 12 (A.30.A)

Connector X-505 Cab/Door Switch Interface to Cab (EH) (Mechanical)

SL57_87382906

4

Cab/Door Switch Interface to Cab (EH) (Mechanical) Description Cavity Circuit ID 1 Door switch signal 250 (YE) 2 1016 (BK/ Door switch ground WH)

Frame Wiring harness - Electrical schematic frame 09 (A.30.A)

Connector X-506 Front Door Washer Pump to Cab (EH) (Mechanical)

SL57_87699736

5

84522361 15/06/2011

A.30.A / 103

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Front Door Washer Pump to Cab (EH) (Mechanical) Description Cavity Circuit ID 1 Washer pump ground 970 (BK) 2 224 (WH) Washer pump signal

Frame Wiring harness - Electrical schematic frame 09 (A.30.A)

Connector X-508 Air Filter Restriction Switch (ISM) (F5C)

SL57_84607243

6

Air Filter Restriction Switch (ISM) (F5C) Description Cavity Circuit ID 1 268 (YE) Air filter sw 1 907 (BL) Air filter sw ground

Frame Wiring harness - Electrical schematic frame 13 (A.30.A) Wiring harness - Electrical schematic frame 12 (A.30.A)

Connector X-509 Air Filter Restriction Switch ground (ISM) Air Filter Restriction Switch ground (ISM) Cavity Circuit ID 1 907 (BL)

Description

Frame Wiring harness - Electrical schematic frame 13 (A.30.A)

Connector X-510 Engine Oil Pressure Switch (F5C)

SL57_87687239

7

Engine Oil Pressure Switch (F5C) Description Cavity Circuit ID 1 Eng oil press sw 255 (YE)

84522361 15/06/2011

A.30.A / 104

Frame Wiring harness - Electrical schematic frame 12 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 15 - Connector X-512 to Connector X-52A Connector X-512 Engine Oil Pressure Switch (ISM)

SL57_84159853

1

Engine Oil Pressure Switch (ISM) Cavity Circuit ID 1 255 (YE)

Description

Frame Wiring harness - Electrical schematic frame 13 (A.30.A)

Connector X-513 Starter Ring Terminal (ISM) Starter Ring Terminal (ISM) Cavity Circuit ID 1 627 (WH)

Description

Frame Wiring harness - Electrical schematic frame 13 (A.30.A)

Connector X-516 Engine Coolant Temperature Sender (ISM) Engine Coolant Temperature Sender (ISM) Description Cavity Circuit ID 1 257 (YE) Coolant temperature sensor

Frame Wiring harness - Electrical schematic frame 13 (A.30.A)

Connector X-517 Fuel Solenoid (ISM)

SL57_87699700

2

Fuel Solenoid (ISM) Cavity Circuit ID 1 602 (WH)

Description

84522361 15/06/2011

A.30.A / 105

Frame Wiring harness - Electrical schematic frame 13 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-521 Fuel Pump (ISM Mechanical)

SL57_87688695

3

Fuel Pump (ISM Mechanical) Description Cavity Circuit ID 1 Engine switched battery power 150 (OR) 2 909 (BK) Fuel Pump to Ground

Frame Wiring harness - Electrical schematic frame 13 (A.30.A)

Connector X-52A Engine/Chassis Harness Interconnect to Engine (EH) (Mechanical)

SL57_87382926

4

Engine/Chassis Harness Interconnect to Engine (EH) (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10 11

Circuit ID 267 (YE) 255 (YE) 257 (YE) 124 (YE) 110 (RD) 602 (WH) 150 (OR) 833 (WH) 127 (OR) 626 (WH) 834 (WH)

12 13

841 (WH) 908 (BK/ WH) 248 (YE)

14

Description Air filter sw Engine oil pressure sw Coolant temperature sensor Engine rpm signal K30 unswitched power Fuel solenoid power Engine switched battery power Thermostat to binary pressure switch Alternator excite Crank signal Binary pressure switch to compressor relay pin 86 A/C compressor relay pin 87 power Clean engine ground EGR ECU K-line

84522361 15/06/2011

A.30.A / 106

Frame Wiring harness - Electrical schematic frame 10 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 16 - Connector X-52B to Connector X-74 Connector X-52B Chassis/Engine Harness Interconnect to Chassis (EH) (Mechanical)

SL57_87382927

1

Chassis/Engine Harness Interconnect to Chassis (EH) (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10 11

Circuit ID 267 (YE) 255 (YE) 257 (YE) 124 (YE) 110 (RD) 602 (WH) 150 (OR) 833 (WH) 127 (OR) 626 (WH) 834 (WH)

12 13

841 (WH) 908 (BK/ WH) 248 (YE)

14

Description Air filter/engine malfunction Engine oil pressure Engine coolant temperature sender Engine rpm signal K30 unswitched power Fuel solenoid signal Engine switched battery power Thermostat to binary pressure switch Alternator excite Crank signal Binary pressure switch to compressor relay pin 86 A/C compressor relay pin 87 power Clean engine ground EGR ECU K-line

Connector X-58 Cab/Seat Interface to Cab (EH) (Mechanical)

SL57_87694154

2

84522361 15/06/2011

A.30.A / 107

Frame Wiring harness - Electrical schematic frame 10 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Cab/Seat Interface to Cab (EH) (Mechanical) Cavity 1 2 3 4

Circuit ID 756 (OR) 933 (BK) 315 (RD) 323 (YE)

Seat Seat Seat Seat

Description accessory power accessory ground sw unswitched power sw cluster input

Frame Wiring harness - Electrical schematic frame 20 (A.30.A)

Connector X-60 Chassis/Engine Harness Telematics Interconnect to Chassis (EH)

SL57_87695582

3

Chassis/Engine Harness Telematics Interconnect to Chassis (EH) Description Cavity Circuit ID 1 Alternator lamp telematics engine on 244 (YE) 2 Open

Frame Wiring harness - Electrical schematic frame 30 (A.30.A)

Connector X-66 2-Cavity Plug to FE Boom (EH) (Mechanical)

SL57_87693821

4

2-Cavity Plug to FE Boom (EH) (Mechanical) Description Cavity Circuit ID A 421 (WH) Multifunction water pump signal power B 988 (BK) Multifunction water pump ground

84522361 15/06/2011

A.30.A / 108

Frame Wiring harness - Electrical schematic frame 29 (A.30.A) (EH) Wiring harness - Electrical schematic frame 24 (A.30.A) (Mech)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-67 EHF Pressure Transducer to Chassis (EH)

5

SL57_87695549

EHF Pressure Transducer to Chassis (EH LG EHF) Description Cavity Circuit ID A 245 (PK) EHF pressure transducer reference B EHF pressure transducer signal 454 (YE) C 1102 (BK/ EHF pressure transducer ground WH)

Frame Wiring harness - Electrical schematic frame 32 (A.30.A)

Connector X-68 Strobe/Cab Harness Interface to Strobe

93109187

6

Strobe/Cab Harness Interface to Strobe (EH) (Mechanical) Description Cavity Circuit ID PWR 738 (VT) Strobe signal power GND 1003 (BK) Strobe ground

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

Connector X-74 HVAC Condenser Fan to Chassis (EH) (Mechanical)

SL57_87692877

7

84522361 15/06/2011

A.30.A / 109

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

HVAC Condenser Fan to Chassis (EH) (Mechanical) Description Cavity Circuit ID A 1084 (BK) HVAC condenser fan ground B 237 (WH) HVAC condenser fan power

84522361 15/06/2011

A.30.A / 110

Frame Wiring harness - Electrical schematic frame 17 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 17 - Connector X-75 to Connector X-9 Connector X-75 Chassis Harness/HVAC Engine Interconnect to HVAC Jumper (EH) (Mechanical)

SL57_87382910

1

Chassis Harness/HVAC Engine Interconnect to HVAC Jumper (EH) (Mechanical) Description Cavity Circuit ID 1 833 (WH) Thermostat to binary pressure switch 2 834 (WH) Binary pressure switch to compressor relay pin 86 3 836 (WH) Compressor fuse

Frame Wiring harness - Electrical schematic frame 17 (A.30.A)

Connector X-76 HVAC High Pressure Switch to HVAC Jumper (EH) (Mechanical)

SL57_87692855

2

HVAC High Pressure Switch to HVAC Jumper (EH) (Mechanical) Description Cavity Circuit ID A 833 (WH) Thermostat to binary pressure switch B 834 (WH) Binary pressure switch to compressor relay pin 86

84522361 15/06/2011

A.30.A / 111

Frame Wiring harness - Electrical schematic frame 17 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-77 Side Lamp DIA Socket to Cab (EH) (Mechanical)

AMP_480115-1

3

Side Lamp DIA Socket to Cab (EH) (Mechanical) Description Cavity Circuit ID A 1085 (BK) DIA side lamp ground B DIA side lamp signal 238 (VT)

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

Connector X-78 Fuel Pump to Engine (F5C)

SL57_87692877

4

Fuel Pump to Engine (F5C) Description Cavity Circuit ID A 239 (WH) F5C fuel pump signal B 1086 (BK) F5C fuel pump ground

Frame Wiring harness - Electrical schematic frame 12 (A.30.A)

Connector X-88 Loader/Chassis Interface to EH Control Valve (EH)

SL57_87382927

5

84522361 15/06/2011

A.30.A / 112

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Loader/Chassis Interface to EH Control Valve (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 510 (WH) 1018 (BL) 511 (WH) 570 (YE) 512 (WH) 1019 (BL) 513 (WH) 571 (YE) 1060 (BK/ WH) 515 (WH) 1020 (BL) 514 (WH) 572 (YE) 236 (OR)

Description Bucket retract signal Bucket return Bucket extend signal Control valve bucket position sensor Loader lower signal Loader return Loader raise signal Control valve loader position sensor Control valve sensor grounds

Frame Wiring harness - Electrical schematic frame 24 (A.30.A)

Proportional aux retract signal Proportional aux return Proportional aux extend signal Control valve aux position sensor Control valve sensor reference voltage

Connector X-9 Ignition Switch to Cab (EH) (Mechanical)

SL57_87693713

6

Ignition Switch to Cab (EH) (Mechanical) Cavity 1 2 3 4 5 6

Circuit ID 140 (RD) 624 (WH) 132 (OR) Open Open 138 (OR)

Description Key sw unswitched battery Key start output Key ignition

Key accessory

84522361 15/06/2011

A.30.A / 113

Frame Wiring harness - Electrical schematic frame 14 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 18 - Connector X-93 to Connector X-AC_COMP Connector X-93 Right-hand Swash Plate Sensor To Chassis (EH)

SL57_87694112

1

Right-hand Swash Plate Sensor To Chassis (EH) Cavity Circuit ID 1 1055 (BK/ WH) 2 223 (PK) 3 575 (YE) 4 576 (YE) 5 221 (PK) 6 1074 (BK/ WH)

Description RH pump angle sensor ground #1

Frame Wiring harness - Electrical schematic frame 27 (A.30.A)

RH pump angle sensor reference #1 RH pump angle #2 RH pump angle #1 RH pump angle sensor reference #2 RH pump angle sensor ground #2

Connector X-94 Left-hand Pump Swash Plate Sensor to Chassis (EH)

SL57_87694112

2

Left-hand Pump Swash Plate Sensor to Chassis (EH) Cavity Circuit ID 1 1054 (BK/ WH) 2 222 (PK) 3 574 (YE) 4 573 (YE) 5 209 (PK) 6 1073 (BK/ WH)

Description LH pump angle sensor ground #1 LH pump angle sensor reference #1 LH pump angle #1 LH pump angle #2 LH pump angle sensor reference #2 LH pump angle sensor ground #2

84522361 15/06/2011

A.30.A / 114

Frame Wiring harness - Electrical schematic frame 27 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-95 Drive Pattern Selector Switch to Cab (EH)

SL57_84159859

3

Drive Pattern Selector Switch to Cab (EH) Cavity 1 2 3 4 5 6 7 8 9 10

Circuit ID 522 (YE) Open 521 (YE) Open 199 (OR) 523 (YE) 197 (OR) 1024 (BL) 1023 (BL) 198 (OR)

Description Control pattern H

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

Control pattern neutral Control pattern sw input power 5 Control pattern ISO Pattern indicator ISO power Pattern indicator H LS output Pattern indicator ISO LS output Pattern indicator H power

Connector X-97 Cab/Dome Lamp Jumper 2-cavity plug to Cab (EH) (Mechanical)

SL57_87695582

4

Cab/Dome Lamp Jumper 2-cavity plug to Cab (EH) Description Cavity Circuit ID 1 151 (OR) Radio/dome lamp/HVAC relay 2 Dome lamp ground 916 (BK)

Frame Wiring harness - Electrical schematic frame 21 (A.30.A)

Cab/Dome Lamp Jumper 2-cavity plug to Cab (Mechanical) Description Cavity Circuit ID 1 Dome lamp power 800 (OR) 2 Dome lamp ground 916 (BK)

84522361 15/06/2011

A.30.A / 115

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-98 EH Seat Switch UCM Diode to Chassis (EH)

cnh_style-24

5

EH Seat Switch UCM Diode to Chassis (EH) Description Cavity Circuit ID A 332 (YE) Seat sw UCM diode in B 330 (YE) EH seat sw UCM diode out

Frame Wiring harness - Electrical schematic frame 20 (A.30.A)

Connector X-99 EH Lap Bar Diode to Chassis (EH)

cnh_style-24

6

EH Lap Bar Diode to Chassis (EH) Description Cavity Circuit ID A 314 (YE) Lap bar/seat belt cluster input B 524 (YE) Seat belt/lap bar operator interlock

Frame Wiring harness - Electrical schematic frame 20 (A.30.A)

Connector X-AC_COMP AC Compressor to HVAC Jumper (EH) (Mechanical)

SL57_87693745

7

AC Compressor to HVAC Jumper (EH) (Mechanical) Description Cavity Circuit ID 1 836 (WH) Compressor fuse

84522361 15/06/2011

A.30.A / 116

Frame Wiring harness - Electrical schematic frame 17 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 19 - Connector X-ACC to Connector X-C01A Connector X-ACC Accessory Power Outlet to Cab (EH) (Mechanical)

SL57_87693325

1

Accessory Power Outlet to Cab (EH) (Mechanical) Description Cavity Circuit ID A Accessory socket ground 952 (BK) B Accessory socket power 801 (RD)

Frame Wiring harness - Electrical schematic frame 06 (A.30.A)

Connector X-AUX_EXT 2nd Auxiliary Extend to Chassis (EH) (Mechanical)

SL57_87695582

2

2nd Auxiliary Extend to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 554 (WH) 2nd aux extend switch output 2 2nd aux extend ground 958 (BK)

84522361 15/06/2011

A.30.A / 117

Frame Wiring harness - Electrical schematic frame 15 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-AUX_RET 2nd Auxiliary Retract to Chassis (EH) (Mechanical)

SL57_87695582

3

2nd Auxiliary Retract to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 552 (WH) 2nd aux retract signal power 2 2nd aux retract ground 959 (BK)

Frame Wiring harness - Electrical schematic frame 15 (A.30.A)

Connector X-BKUP-GND Backup Alarm to Chassis (EH) (Mechanical)

SL57_84159851

4

Backup Alarm to Chassis (EH SM, MD, LG, and LG EHF) (Mechanical SM, MD, and LG) Description Cavity Circuit ID 1 Backup alarm ground 962 (BK)

Frame Wiring harness - Electrical schematic frame 04 (A.30.A)

Connector X-BKUP-PWR Backup Alarm to Chassis (EH) (Mechanical)

SL57_84159851

5

84522361 15/06/2011

A.30.A / 118

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Backup Alarm to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 895 (WH) Backup alarm signal

Frame Wiring harness - Electrical schematic frame 04 (A.30.A)

Connector X-BRK Brake Valve Solenoid to Chassis (EH) (Mechanical)

SL57_87695582

6

Brake Valve Solenoid to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 258 (WH) Park brake valve signal 2 Park brake valve ground 960 (BK)

Frame Wiring harness - Electrical schematic frame 28 (A.30.A) (EH) Wiring harness - Electrical schematic frame 02 (A.30.A) (EH)

Connector X-BRKPRS Brake Pressure Switch to Chassis (EH)

SL57_87680689

7

Brake Pressure Switch to Chassis (EH) Description Cavity Circuit ID 1 Park brake pressure switch 535 (YE) 2 1064 (BK) Park brake pressure switch ground 3 Open

84522361 15/06/2011

A.30.A / 119

Frame Wiring harness - Electrical schematic frame 28 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-C01A Cab/Chassis Options Interface - 1 - to Cab (Mechanical)

SL57_87382924

8

Cab/Chassis Options Interface - 1 - to Cab (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10

Circuit ID 782 (OR) 774 (VT) Open Open 311 (WH) 780 (VT) 312 (WH) Open Open Open

Description Flasher power output LH turn signal chassis power

Loader lockout sw in RH turn signal chassis power Loader lock sw out

84522361 15/06/2011

A.30.A / 120

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 20 - Connector X-C01B to Connector X-CAB_GNDB Connector X-C01B Cab/Chassis Options Interface - 1 - Chassis (Mechanical)

SL57_87382925

1

Cab/Chassis Options Interface - 1 - Chassis (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10

Circuit ID 782 (OR) 774 (VT) Open Open 311 (WH) 780 (VT) 312 (WH) Open Open Open

Description Flasher power output LH turn signal chassis power

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

Loader lockout switch in RH turn signal chassis power Loader lock switch out

Connector X-C02A Cab/Chassis Options Interface (Mechanical)

FRA_54201009

2

84522361 15/06/2011

A.30.A / 121

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Cab/Chassis Options Interface (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10

Circuit ID 129 (OR) 856 (WH) Open 751 (OR) 752 (WH) Open 753 (OR) 750 (WH) Open 141 (WH)

Description Aux elec on/off sw Aux elec on/off sw signal

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

Hydraulic coupler switch in Hydraulic coupler signal High flow switch in Standard high flow signal Options relay signal

Connector X-C02B Cab/Chassis Options Interface -2 - to Chassis (Mechanical)

SL57_84257542

3

Cab/Chassis Options Interface -2 - to Chassis (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10

Circuit ID 129 (OR) 856 (WH) Open 751 (OR) 752 (WH) Open 753 (OR) 750 (WH) Open 141 (WH)

Description Aux elec on/off sw in Aux elec on/off switch signal

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

Hydraulic coupler switch in Hydraulic coupler signal High flow switch in Standard high flow signal Options relay signal

Connector X-C126 Engine Harness / Starter Jumper Interconnect to Engine (F5C)

SL57_87697528

4

84522361 15/06/2011

A.30.A / 122

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Engine Harness / Starter Jumper Interconnect to Engine (F5C) Cavity Circuit ID 1 627 (WH) Crank signal

Description

Frame Wiring harness - Electrical schematic frame 12 (A.30.A)

Connector X-C23 Instrument Cluster to Cab (EH) (Mechanical)

SL57_82028492

5

Instrument Cluster to Cab (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Circuit ID 234 (YE) 264 (YE) 313 (RD) 500 (YE) Open 505 (GN) 602 (WH) 641 (WH) 622 (WH) Open 623 (YE) 328 (YE) Open 303 (WH) 261 (YE) 267 (YE) 251 (YE) 255 (YE) Open 1011 (BK/ WH) 131 (WH) 137 (WH) 301 (OR) 302 (OR) 257 (YE) Open

Description Fuel level sender Hydraulic oil temp sender Instrument cluster unswitched power CAN HI CAN LO Fuel solenoid signal Engine preheat signal Start relay signal Crank cluster input Seat switch cluster input Hydraulic loader interlock signal Hydraulic oil filter Air filter / engine malfunction Door switch signal Engine oil pressure Instrument cluster ground Main power relay signal Accessory relay signal Instrument cluster switched power Instrument cluster switched power Engine coolant temperature sender

84522361 15/06/2011

A.30.A / 123

Frame Wiring harness - Electrical schematic frame 03 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Instrument Cluster to Cab (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Circuit ID 234 (YE) 264 (YE) 313 (RD) 500 (YE) 319 (OR) 505 (GN) 641 (WH) 258 (WH) 622 (WH) 754 (YE) 623 (YE) 323 (YE) 314 (YE) 303 (WH) 261 (YE) 267 (YE) 251 (YE) 255 (YE) 124 (YE) 1011 (BK/ WH) 131 (WH) 137 (WH) 301 (OR) 302 (OR) 257 (YE) 602 (WH)

Description Fuel level sender Hydraulic oil temp sender Instrument cluster unswitched power CAN HI EH aux power CAN LO Fuel solenoid signal Engine preheat signal Start relay signal Park brake switch Crank cluster input Seat switch cluster input Lap bar/seat belt cluster input Hydraulic loader interlock signal Hydraulic oil filter Air filter / engine malfunction Door switch signal Engine oil pressure Engine RPM signal Instrument cluster ground

Frame Wiring harness - Electrical schematic frame 03 (A.30.A)

Main power relay signal Accessory relay signal Instrument cluster switched power Instrument cluster switched power Engine coolant temperature sender Fuel solenoid signal

Connector X-CAB_GNDA Cab Ground to Cab (EH) (Mechanical)

RING TERMINAL

6

Cab Ground to Cab (EH) (Mechanical) Cavity Circuit ID 1 1093 (BK) Cab ground A

Description

84522361 15/06/2011

A.30.A / 124

Frame Wiring harness - Electrical schematic frame 01 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-CAB_GNDB Cab Ground to Cab (EH) (Mechanical)

RING_TERMINAL

7

Cab Ground to Cab (EH) (Mechanical) Cavity Circuit ID 1 1094 (BK) Cab ground B

Description

84522361 15/06/2011

A.30.A / 125

Frame Wiring harness - Electrical schematic frame 01 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 21 - Connector X-CC1A to Connector X-CHS_GND_RR Connector X-CC1A Cab/Chassis Interface - 1 - to Cab (Mechanical)

SL57_87382926

1

Cab/Chassis Interface - 1 - to Cab (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 797 (VT) 795 (VT) 248 (YE) 503 (YE) 791 (VT) 124 (YE) 910 (BK/ WH) 234 (YE) 319 (OR) 115 (RD) 264 (YE) 310 (RD) 602 (WH) 790 (VT)

Description Light relay #1 front work lamp power Side lamp power signal EGR ECU K-line CAN HI Lamp switch road lamp signal Engine RPM signal Instrument cluster ground

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

Fuel level sender EH aux power Beacon and accessory fuse output Hydraulic oil temperature sender Unswitched battery power Fuel solenoid signal Lamp switch work lamp signal

Connector X-CC1B Chassis/Cab Interface - 1 - to Chassis (Mechanical)

SL57_87382927

2

84522361 15/06/2011

A.30.A / 126

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Chassis/Cab Interface - 1 - to Chassis (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 797 (VT) 795 (VT) 248 (YE) 503 (YE) 791 (VT) 124 (YE) 910 (BK/ WH) 234 (YE) 319 (OR) 115 (RD) 264 (YE) 310 (RD) 602 (WH) 790 (VT)

Description Light relay #1 front work lamp power Side lamp power signal EGR ECU K-line CAN HI Lamp switch road lamp signal Engine RPM signal Instrument cluster ground

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

Fuel level sender EH aux power Beacon and accessory fuse output Hydraulic oil temperature sender Unswitched battery power Fuel solenoid signal Lamp switch work lamp signal

Connector X-CC2A Cab/Chassis Interface - 2 - to Cab (Mechanical)

SL57_87382927

3

Cab/Chassis Interface - 2 - to Cab (Mechanical) Description Frame Cavity Circuit ID 1 134 (OR) Wiper / seat acc / radio / dome lamp / defrost Wiring harness - Electrical schematic frame 02 (A.30.A) sw / HVAC relay / self level sw power 2 641 (WH) Engine preheat signal 3 258 (WH) Park brake valve signal 4 Instrument cluster switched power 309 (OR) 5 303 (WH) Hydraulic loader interlock signal 6 261 (YE) Hydraulic oil filter 7 267 (YE) Air filter / engine malfunction 8 Engine oil pressure 255 (YE) 9 843 (OR) HVAC fuse to HVAC box voltage drop circuit 10 628 (WH) Instrument cluster / key switch to start relay 11 Main power relay signal 133 (OR) 12 Accessory relay signal 139 (OR) 13 Engine coolant temperature sender 257 (YE) 14 822 (OR) HVAC water valve power

84522361 15/06/2011

A.30.A / 127

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-CC2B Chassis/Cab Interface - 2 - to Chassis (Mechanical)

SL57_87382926

4

Cab/Chassis Interface - 2 - to Chassis (Mechanica) Description Frame Cavity Circuit ID 1 134 (OR) Wiper / seat acc / radio / dome lamp / defrost Wiring harness - Electrical schematic frame 02 (A.30.A) sw / HVAC relay / self level sw power 2 641 (WH) Engine preheat signal 3 258 (WH) Park brake valve signal 4 Instrument cluster switched power 309 (OR) 5 303 (WH) Hydraulic loader interlock signal 6 261 (YE) Hydraulic oil filter 7 267 (YE) Air filter / engine malfunction 8 Engine oil pressure 255 (YE) 9 843 (OR) HVAC fuse to HVAC box voltage drop circuit 10 628 (WH) Instrument cluster / key switch to start relay 11 Main power relay signal 133 (OR) 12 Accessory relay signal 139 (OR) 13 Engine coolant temperature sender 257 (YE) 14 822 (OR) HVAC water valve power Connector X-CC3A Cab/Chassis Interface - 3 - to Cab (Mechanical)

SL57_84394888

5

84522361 15/06/2011

A.30.A / 128

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Cab/Chassis Interface - 3 - to Cab (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13

Circuit ID 404 (WH) 565 (VT) 824 (YE) 504 (GN) 792 (VT) 841 (WH) 833 (WH) 844 (OR) 307 (YE) 123 (OR) 237 (WH) 836 (RD) 834 (WH)

14

233 (OR)

Description Self level switch output power 2 speed indicator HVAC temp control signal CAN lo Lamp sw work and side lamp signal A/C compressor relay pin 87 power Thermostat to binary pressure switch HVAC fuse to HVAC box voltage drop circuit RH grip park brake sw output Lamp sw power HVAC condenser fan power Compressor condenser fan fuse Binary pressure switch to compressor relay pin 86 Wiper / washer sw power

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

Connector X-CC3B Chassis/Cab Interface - 3 - to Chassis (Mechanical)

SL57_84394888

6

Cab/Chassis Interface - 3 - to Cab (Mechanical) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13

Circuit ID 404 (WH) 565 (VT) 824 (YE) 504 (GN) 792 (VT) 841 (WH) 833 (WH) 844 (OR) 307 (YE) 123 (OR) 237 (WH) 836 (RD) 834 (WH)

14

233 (OR)

Description Self level switch output power 2 speed indicator HVAC temp control signal CAN LO Lamp sw work and side lamp signal A/C compressor relay pin 87 power Thermostat to binary pressure switch HVAC fuse to HVAC box voltage drop circuit RH grip park brake sw output Lamp sw power HVAC condenser fan power Compressor condenser fan fuse Binary pressure switch to compressor relay pin 86 Wiper / washer sw power

84522361 15/06/2011

A.30.A / 129

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-CHGPRS Hydraulic Charge Pressure Switch to Chassis (EH)

SL57_84062580

7

Hydraulic Charge Pressure Switch to Chassis (EH) Description Cavity Circuit ID 1 Hydraulic charge pressure switch 262 (YE) 2 Hydraulic charge pressure switch ground 954 (BK) 3 Open

Frame Wiring harness - Electrical schematic frame 28 (A.30.A)

Connector X-CHS_GND_FRT to Chassis (EH) (Mechanical)

RING_TERMINAL

8

CHS_GND_FRT to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 983 (BK) CHS_GND_FRT

Frame Wiring harness - Electrical schematic frame 01 (A.30.A)

Connector X-CHS_GND_RR to Chassis (EH) (Mechanical)

RING_TERMINAL

9

84522361 15/06/2011

A.30.A / 130

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

CHS_GND_RR to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 967 (BK) CHS_GND_RR

84522361 15/06/2011

A.30.A / 131

Frame Wiring harness - Electrical schematic frame 01 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 22 - Connector X-CN1A to Connector X-CN4A L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Connector X-CN1A UCM to Chassis (EH)

87410948

1

UCM to Chassis (EH) Cavity Circuit ID 1 1075 (BK/ WH) 2 Open 3 Open 4 Open 5 Open 6 Open 7 1076 (BK/ WH) 8 202 (PK) 9 200 (PK) 10 Open 11 Open 12 Open 13 1018 (BL) 14 525 (YE) 15 Open 16 124 (YE) 17 Open 18 Open 19 1022 (BL) 20 189 (RD) 21 Open 22 1020 (BL) 23 Open 24 515 (WH) 25 Open 26 240 (OR)

Description UCM ground 1A.01

UCM ground 1A.07 Sensor supply 1 Sensor supply 3

Bucket return UCM wake-up Engine RPM signal

Drive reverse return UCM unswitched battery fuse out Proportional aux return Proportional aux retract signal 5V ref supply fuse

84522361 15/06/2011

A.30.A / 132

Frame Wiring harness - Electrical schematic frame 26 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-CN1B UCM to Chassis (EH)

SL57_87410946

2

UCM to Chassis (EH) Cavity Circuit ID 1 1026 (BK/ WH) 2 Open 3 Open 4 Open 5 Open 6 Open 7 Open 8 Open 9 1025 (BK/ WH) 10 Open 11 Open 12 Open 13 560 (GN) 14 Open 15 521 (YE) 16 Open 17 Open 18 Open 19 Open 20 Open 21 Open 22 Open 23 Open 24 Open 25 507 (GN) 26 128 (OR) 27 126 (OR) 28 Open 29 580 (VT) 30 579 (VT) 31 166 (OR) 32 201 (OR) 33 514 (WH) 34 502 (YE)

Description UCM ground 1B.34

UCM ground 1B.26

RH ua2 Y sensor output Control pattern neutral

CAN lo Switched power supply prop aux extend Switched power supply prop aux retract Brake lamp circuit output #2 Brake lamp circuit output #1 Switched power brake lamp Switched power brake lamp Proportional aux extend signal CAN hi

84522361 15/06/2011

A.30.A / 133

Frame Wiring harness - Electrical schematic frame 26 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-CN2A UCM to Chassis (EH)

AMP_0-1473416-1

3

UCM to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Circuit ID Open 164 (OR) 165 (OR) 536 (WH) 537 (WH) Open 159 (OR) 518 (WH) 262 (YE) Open Open Open 163 (OR) 517 (WH) Open Open Open Open Open 1077 (BK/ WH) Open Open 1024 (BL) 750 (WH) 1027 (BK/ WH)

Description Left pump reverse power Right pump reverse power Loader pilot interlock Loader port lock Switched power port/pilot lock Pump right reverse Hydraulic charge pressure switch

Switched power port/pilot lock Pump left reverse

UCM ground 2A.20

Pattern indicator H LS output Standard high flow signal UCM ground 2A.26

84522361 15/06/2011

A.30.A / 134

Frame Wiring harness - Electrical schematic frame 26 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-CN2B UCM to Chassis (EH)

87410947

4

UCM to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Circuit ID Open 1023 (BL) Open Open Open Open 1019 (BL) 1099 (BL) 154 (OR) Open Open Open 535 (YE) 562 (GN) Open Open 158 (OR) Open Open 522 (YE) 523 (YE) 754 (YE) 398 (YE) 532 (YE) 1021 (BL) 1028 (BK/ WH) 531 (YE) 547 (YE) Open Open 568 (GN) 576 (YE) 575 (YE) 1029 (BK/ WH)

Description Pattern indicator ISO LS output

Loader return EHF return Switched power loader control

Park brake pressure switch LH ua2 X sensor output

Switched power loader control

Control pattern H Control pattern ISO Park brake switch Loader lockout switch N.O. output (valve off) Engine start input Drive forward return UCM ground 2B.26 Loader float switch input Proportional aux switch output signal #2

LH ua2 Y sensor output RH pump angle #1 RH pump angle #2 UCM ground 2B.34

84522361 15/06/2011

A.30.A / 135

Frame Wiring harness - Electrical schematic frame 26 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-CN3A UCM to Chassis (EH)

SL57_84130757

5

UCM to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Circuit ID Open 168 (OR) 169 (OR) 258 (WH) Open 430 (WH) 170 (OR) Open 574 (YE) 573 (YE) 548 (GN) 454 (YE) 171 (OR) Open Open Open Open Open 431 (WH) 1030 (BK/ WH) 120 (OR) 512 (WH) 303 (WH) 545 (YE) Open 1031 (BK/ WH)

Description Switch power park brake Switched power park brake Park brake valve signal EHF retract signal Switched power two speed LH pump angle #1 LH pump angle #2 RH ua2 X sensor output EHF pressure transducer signal Switched power two speed

EHF extend signal UCM ground 3A.20 Pump forward power Loader lower signal Hydraulic loader interlock signal Throttle position UCM ground 3A.26

84522361 15/06/2011

A.30.A / 136

Frame Wiring harness - Electrical schematic frame 26 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-CN3B UCM to Chassis (EH)

SL57_84130760

6

UCM to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Circuit ID Open Open 167 (OR) Open Open 513 (WH) Open 142 (OR) 147 (OR) Open 755 (WH) 570 (YE) 571 (YE) 572 (YE) Open Open 510 (WH) 895 (WH) 312 (YE) Open Open Open Open Open Open 1032 (BK/ WH) Open Open 554 (WH) 526 (YE) 552 (WH) 519 (WH) 516 (WH) 1033 (BK/ WH)

Description

Switched power backup alarm

Loader raise signal Switched power bucket control Switched power bucket control High performance high flow signal Control valve bucket position sensor Control valve loader position sensor Control valve aux position sensor

Bucket retract signal Bckup alarm signal Loader lock switch N.C. output (valve on)

UCM ground 3B.26

Seat switch operator interlock 2nd aux retract signal power Pump right forward Pump left forward UCM ground 3B.34

84522361 15/06/2011

A.30.A / 137

Frame Wiring harness - Electrical schematic frame 26 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-CN4A UCM to Chassis (EH)

AMP_0-1473416-1

7

UCM to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Circuit ID 0060 (OR) Open Open Open Open Open Open 0061 (OR) Open 524 (YE) Open Open Open Open Open Open 561 (WH) 569 (WH) 511 (WH) 1034 (BK/ WH) Open Open Open 549 (WH) 567 (WH) 1035 (BK/ WH)

Description Switched power bucket control

Switched power bucket control Seat belt/lap bar operator interlock

RH ua1 Y sensor output LH ua1 Y sensor output Bucket extend signal UCM ground 4A.20

RH ua1 X sensor output LH ua1 X sensor output UCM ground 4A.26

84522361 15/06/2011

A.30.A / 138

Frame Wiring harness - Electrical schematic frame 26 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 23 - Connector X-CN4B to Connector X-ECC2A X-CN4B UCM to Chassis (EH)

87410947

1

UCM to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Description Circuit ID Open Open Open Open Open Open Open Open Open Open Open Open 423 (YE) Open 541 (YE) 2 speed UCM input Open Open Open Open Open 546 (YE) Proportional aux switch output signal #1 Open Open Open Open 1036 (BK/ WH) Open Open Open Open Open Open 1037 (BK/ WH)

UCM ground 4B.27

UCM ground 4B.34 84522361 15/06/2011

A.30.A / 139

Frame Wiring harness - Electrical schematic frame 26 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-CPLR Hydraulic Coupler Valve Solenoid to Chassis (EH) (Mechanical)

SL57_87695582

2

Hydraulic Coupler Valve Solenoid to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 752 (WH) Hydraulic coupler signal 2 Hydraulic coupler valve ground 978 (BK)

Frame Wiring harness - Electrical schematic frame 25 (A.30.A) (EH) Wiring harness - Electrical schematic frame 02 (A.30.A) (Mech)

Connector X-CTS Turn Signal Switch to Cab (EH) (Mechanical)

SL57_87697780

3

Turn Signal Switch to Cab (EH) (Mechanical) Cavity A B C D E F

Description Circuit ID Open Open Open 777 (VT) Cab turn signal switch RH 783 (OR) Flasher power output 775 (VT) Cab turn signal switch LH

84522361 15/06/2011

A.30.A / 140

Frame Wiring harness - Electrical schematic frame 16 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-DIAG CAN Diagnostic Connector to Cab (EH) (Mechanical)

SL57_87516075

4

CAN Diagnostic Connector to Cab (EH) (Mechanical) Cavity Circuit ID A 961 (BK/ WH) B 162 (RD) C 501 (YE) D 506 (GN) E 248 (YE) F Open G Open H Open I Open J Open

Description EST connectors ground

Frame Wiring harness - Electrical schematic frame 31 (A.30.A) (EH) Wiring harness - Electrical schematic frame 25 (A.30.A) (Mech)

Unswitched battery power CAN hi CAN lo EGR ECU K-line

Connector X-ECC1A EH Chassis / Cab Interface -1- to Cab (EH)

SL57_87382926

5

84522361 15/06/2011

A.30.A / 141

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

EH Chassis / Cab Interface -1- to Cab (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 797 (VT) 795 (VT) 503 (YE) 504 (GN) 791 (VT) 314 (YE) 910 (BK/ WH) 234 (YE) 357 (OR) 115 (RD) 264 (YE) 310 (RD) 602 (WH) 790 (VT)

Description Light relay #1 front work lamp power Side lamp power signal CAN hi CAN lo Lamp sw road lamp signal Lap bar / seat belt cluster input Instrument cluster ground

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

Fuel level sender Main power relay ignition fuse Beacon power Hydraulic oil temp sender Unswitched battery power Fuel solenoid signal Lamp sw work lamp signal

Connector X-ECC1B EH Chassis / Cab Interface -1- to Chassis (EH)

SL57_87382927

6

EH Chassis / Cab Interface -1- to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 797 (VT) 795 (VT) 503 (YE) 504 (GN) 791 (VT) 314 (YE) 910 (BK/ WH) 234 (YE) 357 (OR) 115 (RD) 264 (YE) 310 (RD) 602 (WH) 790 (VT)

Description Light relay #1 front work lamp power Side lamp power signal CAN hi CAN lo Lamp switch road lamp signal Lap bar / seat belt cluster input Instrument cluster ground Fuel level sender Main power relay ignition fuse to cab Beacon and accessory fuse output Hydraulic oil temperature sender Unswitched battery power Fuel solenoid signal Lamp switch work lamp signal

84522361 15/06/2011

A.30.A / 142

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-ECC2A EH Chassis / Cab Interface -2- to Cab (EH)

SL57_87382927

7

EH Chassis / Cab Interface -2- to Cab (EH) Description Frame Cavity Circuit ID 1 134 (OR) Wiper / seat acc / radio / dome lamp / dfrst sw Wiring harness - Electrical schematic frame 02 (A.30.A) / HVAC relay /self level sw power 2 641 (WH) Engine preheat signal 3 329 (YE) Seat switch UCM input 4 309 (OR) Instrument cluster switched power 5 303 (WH) Hydraulic loader interlock signal 6 261 (YE) Hydraulic oil filter 7 267 (YE) Air filter / engine malfunction 8 Engine oil pressure 255 (YE) 9 843 (OR) HVAC fuse to HVAC box - voltage drop parallel circuit 10 628 (WH) Instrument cluster / key switch to start relay 11 133 (OR) Main power relay signal 12 175 (WH) EH acc relay chassis interface signal 13 Engine coolant temperature sender 257 (YE) 14 822 (OR) HVAC water valve power

84522361 15/06/2011

A.30.A / 143

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 24 - Connector X-ECC2B to Connector X-ECC6B L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Connector X-ECC2B EH Chassis / Cab Interface -2- to Chassis (EH)

SL57_87382926

1

EH Chassis / Cab Interface -2- to Chassis (EH) Description Frame Cavity Circuit ID 1 134 (OR) Wiper / seat acc / radio / dome lamp / dfrst sw Wiring harness - Electrical schematic frame 02 (A.30.A) / HVAC relay / self level sw power 2 641 (WH) Engine preheat signal 3 329 (YE) Seat switch UCM input 4 309 (OR) Instrument cluster switched power 5 303 (WH) Hydraulic loader interlock signal 6 261 (YE) Hydraulic oil filter 7 267 (YE) Air filter / engine malfunction 8 Engine oil pressure 255 (YE) 9 843 (OR) HVAC fuse to HVAC box voltage drop parallel circuit 10 628 (WH) Instrument cluster / key switch to start relay 11 133 (OR) Main power relay signal 12 175 (WH) EH ACC relay chassis interface signal 13 Engine coolant temperature sender 257 (YE) 14 822 (OR) HVAC water valve power Connector X-ECC3A EH Chassis / Cab Interface -3- to Cab (EH)

SL57_84394888

2

84522361 15/06/2011

A.30.A / 144

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

EH Chassis / Cab Interface -3- to Cab (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13

Circuit ID 404 (WH) 248 (YE) 824 (YE) 1090 (BK/ WH) 792 (VT) 1023 (BL) 833 (WH) 1024 (BL) 754 (YE) 123 (OR) 541 (YE) 531 (YE) 834 (WH)

14

844 (OR)

Description Self level switch output power EGR ECU K-line HVAC temp control signal UJM sensor grounds 4A.20

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

Lamp sw work and side lamp signal Pattern indicator ISO LS output Thermostat to binary pressure switch Pattern indicator H LS output Park brake sw Lamp sw power 2 speed UCM input Loader float switch input Binary pressure switch to compressor relay pin 86 HVAC fuse to HVAC box voltage drop parallel circuit

Connector X-ECC3B EH Chassis / Cab Interface -3- to Chassis (EH)

SL57_84394890

3

EH Chassis / Cab Interface -3- to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13

Circuit ID 404 (WH) 248 (YE) 824 (YE) 1090 (BK/ WH) 792 (VT) 1023 (BL) 833 (WH) 1024 (BL) 754 (YE) 123 (OR) 541 (YE) 531 (YE) 834 (WH)

14

844 (OR)

Description Self level switch output power EGR ECU K-line HVAC temperature control signal UJM sensor grounds 4A.20 Lamp switch work and side lamp signal Pattern indicator ISO LS output Thermostat to binary pressure switch Pattern indicator H LS output Park brake switch Lamp switch power 2 speed UCM input Loader float switch input Binary pressure switch to compressor relay pin 86 HVAC fuse to HVAC box - voltage drop parallel circuit

84522361 15/06/2011

A.30.A / 145

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-ECC4A EH Chassis / Cab Interface -4- to Cab (EH)

SL57_84394890

4

EH Chassis / Cab Interface -4- to Cab (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 769 (OR) 774 (VT) 398 (YE) 521 (YE) 237 (WH) 780 (VT) 841 (OR) 836 (RD) 522 (YE) 233 (OR) 523 (YE) 312 (YE) 548 (GN) 560 (GN)

Description Flasher module output power LH turn signal chassis power Loader lockout sw N. O. output (valve off) Control pattern neutral HVAC condenser fan power RH turn signal chassis power A/C compressor relay pin 87 power Compressor / condenser fan fuse Control pattern H Wiper / washer sw power Control pattern ISO Loader lock sw N. C. output (valve on) RH UA2 X sensor output RH UA2 Y sensor output

Frame Wiring harness - Electrical schematic frame 25 (A.30.A)

Connector X-ECC4B EH Chassis / Cab Interface -4- to Chassis (EH)

SL57_84394888

5

84522361 15/06/2011

A.30.A / 146

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

EH Chassis / Cab Interface -4- to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 769 (OR) 774 (VT) 398 (YE) 521 (YE) 237 (WH) 780 (VT) 841 (WH) 836 (RD) 522 (YE) 233 (OR) 523 (YE) 312 (YE) 548 (GN) 560 (GN)

Description Frame Flasher module output power Wiring harness - Electrical schematic frame 25 (A.30.A) LH turn signal chassis power Loader lockout switch N. O. output (valve off) Control pattern neutral HVAC condenser fan power RH turn signal chassis power A/C compressor relay pin 87 power Compressor / condenser fan fuse Control pattern H RH pump angle sensor reference #1 Control pattern ISO Loader lock switch N. C. output (valve on) RH UA2 X sensor output RH UA2 Y sensor output

Connector X-ECC5A EH Chassis / Cab Interface -5- to Cab (EH) EH Chassis / Cab Interface -5- to Cab (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 129 (OR) 856 (WH) 549 (WH) 744 (OR) 752 (WH) 755 (WH) 831 (WH) 750 (WH) 561 (WH) 1051 (BK/ WH) 562 (GN) 568 (GN) 554 (WH) 552 (WH)

Description Aux elec on / off switch in Aux elec on / off switch signal RH UA1 X sensor output High flow / hydraulic coupler switch power Hydraulic coupler signal High performance high flow signal Ride control valve solenoid signal Standard high flow signal RH UA1 Y sensor output UJM sensor grounds 2A.26

Frame Wiring harness - Electrical schematic frame 25 (A.30.A)

LH UA2 x sensor output LH UA2 Y sensor output 2nd aux extend switch output 2nd aux retract signal power

Connector X-ECC5B EH Chassis / Cab Interface -5- to Chassis (EH)

SL57_84394889

6

84522361 15/06/2011

A.30.A / 147

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

EH Chassis / Cab Interface -5- to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 129 (OR) 856 (WH) 549 (WH) 744 (OR) 752 (WH) 755 (WH) 831 (WH) 750 (WH) 561 (WH) 1051 (BK/ WH) 562 (GN) 568 (GN) 554 (WH) 552 (WH)

Description Aux elec on/off switch in Aux elec on/off switch signal RH UA1 X sensor output High flow / hydraulic coupler switch power Hydraulic coupler signal High performance high flow signal Ride control valve solenoid signal Standard high flow signal RH UA1 Y sensor output UJM sensor grounds 2A.26

Frame Wiring harness - Electrical schematic frame 25 (A.30.A)

LH UA2 X sensor output LH UA2 Y sensor output 2nd aux extend switch output 2nd aux retract signal power

Connector X-ECC6A EH Chassis / Cab Interface -6- to Cab (EH)

SL57_84394889

7

EH Chassis / Cab Interface -6- to Cab (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 567 (WH) 569 (WH) 354 (OR) 410 (WH) 411 (TN) 416 (VT) 417 (RD) 418 (GY) 419 (LG) 892 (WH) 546 (YE) 210 (PK) 200 (PK) 547 (YE)

Description LH UA1 X sensor output LH UA1 Y sensor output Handle multifunction #1, #2, #3 power RH handle multifunction #1 up RH handle multifunction #1 down Handle multifunction #2 up Handle multifunction #2 down LH handle multifunction #3 up LH handle multifunction #3 down Horn power signal Proportional aux switch output signal #2 Cab sensor supply 1 Sensor supply 3 Proportional aux switch output signal #1

84522361 15/06/2011

A.30.A / 148

Frame Wiring harness - Electrical schematic frame 25 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-ECC6B EH Chassis / Cab Interface -6- to Chassis (EH) EH Chassis / Cab Interface -6- to Chassis (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Circuit ID 567 (WH) 569 (WH) 354 (OR) 410 (WH) 411 (TN) 416 (VT) 417 (RD) 418 (GY) 419 (LG) 892 (WH) 546 (YE) 210 (PK) 200 (PK) 547 (YE)

Description LH UA1 X sensor output LH UA1 Y sensor output Handle multifunction #1, #2, #3 power RH handle multifunction #1 up RH handle multifunction #1 down Handle multifunction #2 up Handle multifunction #2 down LH handle multifunction #3 up LH handle multifunction #3 down Horn power signal Proportional aux switch output signal #1 Cab sensor supply 1 Sensor supply 3 Proportional aux switch output signal #2

84522361 15/06/2011

A.30.A / 149

Frame Wiring harness - Electrical schematic frame 25 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 25 - Connector X-EGR to Connector X-FUEL Connector X-EGR ECU to Engine (F5C)

SL57_84279936

1

ECU to Engine (F5C) Cavity Circuit ID 1 675 (WH) 2 Open 3 900 (BK/ WH) 4 Open 5 242 (OR) 6 248 (YE) 7 212 (PK) 8 205 (PK) 9 1072 (BK/ WH) 10 902 (BL) 11 903 (BL) 12 904 (BL) 13 Open 14 110 (RD) 15 Open 16 Open 17 266 (YE) 18 625 (YE) 19 253 (YE) 20 235 (YE) 21 254 (YE) 22 252 (YE) 23 905 (BL) 24 Open 25 216 (YE)

Description EGR valve control signal (PWM) EGR ECU ground

EGR ECU switched battery power EGR ECU K-line Boost sensor supply EGR valve position sensor supply EGR ECU K-line ground EGR valve position sensor ground Coolant temperature sensor ground Boost sensor ground K30 unswitched power

Diagnostic lamp K50 crank signal EGR valve position sensor signal Coolant temperature signal Boost temperature signal Boost pressure signal Engine speed sensor B Engine speed sensor A

84522361 15/06/2011

A.30.A / 150

Frame Wiring harness - Electrical schematic frame 12 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-EH_POS1 Battery Power to Chassis (EH)

RING TERMINAL

2

Battery Power to Chassis (EH) Description Cavity Circuit ID 1 0054 (RD) EH power term1

Frame Wiring harness - Electrical schematic frame 10 (A.30.A)

Connector X-EH_POS2 Battery Power to Chassis (EH)

RING TERMINAL

3

Battery Power to Chassis (EH) Description Cavity Circuit ID 1 0055 (RD) EH power term2

Frame Wiring harness - Electrical schematic frame 10 (A.30.A)

Connector X-FPT Harness Interconnect to Engine (F5C)

SL57_87699386

4

84522361 15/06/2011

A.30.A / 151

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Harness Interconnect to Engine (F5C) Cavity Circuit ID 1A 675 (WH) 1B 906 (BK/ WH) 1C Open 2A Open 2B 212 (PK) 2C 216 (YE) 3A 205 (PK) 3B 254 (YE) 3C 905 (BL) 4A 253 (YE) 4B 903 (BL) 4C Open 5A 902 (BL) 5B 235 (YE) 5C Open 6A 904 (BL) 6B Open 6C Open 7A 252 (YE) 7B Open 7C Open 8A Open 8B Open 8C Open

Description EGR valve control signal (PWM) EGR valve control ground (PWM)

Frame Wiring harness - Electrical schematic frame 12 (A.30.A)

Boost sensor supply Engine speed sensor A EGR valve position sensor supply Boost temperature signal Engine speed sensor B EGR valve position sensor signal Coolant temperature sensor ground EGR valve position sensor ground Coolant temperature signal Boost sensor ground

Boost pressure signal

Connector X-FUEL Fuel Solenoid to Engine (F5C)

SL57_87687239

5

Fuel Solenoid to Engine (F5C) Description Cavity Circuit ID 1 602 (WH) Fuel solenoid power

84522361 15/06/2011

A.30.A / 152

Frame Wiring harness - Electrical schematic frame 12 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 26 - Connector X-FUSE1 to Connector X-HORN-GND Connector X-FUSE1 Power Distribution to Chassis (Mechanical)

SL57_84255438

1

Power Distribution to Chassis (Mechanical) Description Cavity Circuit ID A1 830 (OR) HVAC relay fuse power A2 A3 A4 A5 A6 A7

820 (OR) 629 (OR) 944 (BK) 707 (VT)

A8 A9 A10 A11

945 (BK) 116 (RD) 710 (VT)

A12 B1 B2 B3 B4 B5 B6 B7

946 (BK) 243 (OR) 233 (OR) Open 628 (WH) Open 112 (RD) 709 (WH)

B8 B9 B10 B11 B12

Open 113 (RD) 325 (WH) Open 788 (VT)

C1

135 (OR)

C2

134 (OR)

C3 C4 C5

350 (OR) 351 (OR) 835 (RD)

Frame Wiring harness - Electrical schematic frame 04 (A.30.A)

HVAC relay fuse power Crank signal Crank relay pin 85 coil ground Light relay #2 pin 87 side lamp switch rear work lamp output Light relay #2 pin 85 coil ground Light relay #1 pin 87 unswitched power Road lamp configuration front work lamp control signal Light relay #1 pin 85 coil ground Wiper / washer switch power from Acc relay Wiper / washer switch power Instrument cluster / key switch to start relay Crank relay pin 30 unswitched power Lamp switch work and side lamp signal to lamp relay #2 Light relay #2 pin 30 unswitched power Light relay #1 pin 86 work lamp switch signal Light relay #1 pin 30 to fuse (front work lamp power) Wiper / seat acc / radio / dome lamp / defrost switch / HVAC relay / self level Wiper / seat acc / radio / dome lamp / defrost switch / HVAC relay / self level Main power relay ignition fuse Main power relay ignition fuse Compressor / condenser fan fuse 84522361 15/06/2011

A.30.A / 153

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Cavity C6 C7 C8 C9 C10 C11 C12 D1 D2 D3

Circuit ID 836 (RD) 136 (OR) Open 947 (BK) 125 (OR) Open 948 (BK) 160 (RD) 161 (RD) 326 (OR)

D4

300 (OR)

D5 D6 D7 D8 D9 D10 D11 D12 E1

114 (RD) 196 (RD) 144 (OR) Open 118 (RD) 139 (OR) Open 117 (RD) 788 (VT)

E2 E3 E4

797 (VT) 792 (VT) 708 (VT)

E5 E6 E7 E8 E9 E10 E11 E12

705 (VT) 706 (VT) 701 (VT) 703 (VT) 700 (VT) 704 (VT) 629 (OR) 626 (WH)

Description Compressor / condenser fan fuse Main power relay pin 87 output

Frame

Main power relay pin 85 coil ground Accessory relay pin 87 output power Accessory relay pin 85 coil ground Unswitched battery power Unswitched battery power Main power relay instrument cluster ignition fuse Main power relay instrument cluster ignition fuse Beacon and accessory fuse output Beacon and accessory fuse output Main power relay signal Main power relay pin 30 unswitched battery Accessory relay signal Accessory relay pin 30 unswitched power Light relay #1 pin 30 to fuse (front work lamp power) Light relay #1 front work lamp power Lamp switch work and side lamp signal Lamp switch work and side lamp signal and side lamp fuse out Rear work lamp fuse in Rear work lamp fuse out Tail lamp splice LH tail lamp fuse in Tail lamp splice LH tail lamp fuse out Tail lamp splice LH tail lamp fuse in Tail lamp splice LH tail lamp fuse out Crank signal Crank signal

Connector X-FUSE2 Power Distribution to Chassis (Mechanical)

SL57_84255438

2

84522361 15/06/2011

A.30.A / 154

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Power Distribution to Chassis (Mechanical) Cavity Circuit ID A1 Open A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12

Open Open Open Open Open Open Open Open 743 (OR) Open 972 (BK) Open Open Open Open Open Open Open Open Open 148 (WH) Open 104 (RD)

C1

356 (OR)

C2

420 (OR)

C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 E1

Open Open Open Open Open Open Open 149 (OR) Open 974 (BK) 355 (OR) 354 (OR) Open Open Open Open Open Open Open 146 (WH) Open 103 (RD) 145 (OR)

Description

Light relay #1 pin 87 unswitched power Light relay #1 pin 85 coil ground

Light relay #1 pin 86 work lamp switch signal Light relay #1 pin 30 to fuse (front work lamp power) Wiper / seat acc / radio / dome lamp / defrost switch / HVAC relay / self level Wiper / seat acc / radio / dome lamp / defrost switch / HVAC relay / self level

Accessory relay pin 87 output power Accessory relay pin 85 coil ground Unswitched battery power Unswitched battery power

Accessory relay signal Accessory relay pin 30 unswitched power Light relay #1 pin 30 to fuse (front work lamp power) 84522361 15/06/2011

A.30.A / 155

Frame Wiring harness - Electrical schematic frame 05 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Cavity E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12

Circuit ID 129 (OR) Open Open 714 (VT) 716 (VT) 715 (VT) 719 (VT) 101 (RD) 156 (RD) 743 (OR) 744 (OR)

Description Light relay #1 front work lamp power

Frame

Rear work lamp fuse in Rear work lamp fuse out Tail lamp splice LH tail lamp fuse in Tail lamp splice LH tail lamp fuse out Tail lamp splice LH tail lamp fuse in Tail lamp splice LH tail lamp fuse out Crank signal Crank signal

Connector X-HFLO High Flow Valve Solenoid to Chassis (EH) (Mech)

SL57_87695582

3

High Flow Valve Solenoid to Chassis (EH) (Mech) Description Cavity Circuit ID 1 750 (WH) Standard high flow signal 2 976 (BK) Standard high flow valve ground

Frame Wiring harness - Electrical schematic frame 25 (A.30.A) (EH) Wiring harness - Electrical schematic frame 02 (A.30.A) (Mech)

Connector X-HORN-GND Horn to Chassis (EH) (Mech)

SL57_87697629

4

Horn to Chassis (EH) (Mech) Cavity Circuit ID 1 Horn ground 955 (BK)

Description

84522361 15/06/2011

A.30.A / 156

Frame Wiring harness - Electrical schematic frame 07 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 27 - Connector X-HORN-PWR to Connector X-K-C4 - Connector X-HORN-PWR Horn to Chassis (EH) (Mechanical)

SL57_87697629

1

Horn to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 892 (WH) Horn power signal

Frame Wiring harness - Electrical schematic frame 07 (A.30.A)

Connector X-HVC1 Cab/HVAC Interconnect to Cab (EH) (Mechanical)

SL57_87382926

2

84522361 15/06/2011

A.30.A / 157

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Cab/HVAC Interconnect to Cab (EH) (Mechanical) Cavity 1 2 3 4 5 6

Circuit ID 935 (BK) 838 (RD) 828 (WH) 827 (WH) 850 (WH) 837 (WH)

7 8

833 (WH) 834 (WH)

9

1012 (BK/ WH) 842 (OR) 143 (OR) 841 (OR) Open 845 (OR)

10 11 12 13 14

Description HVAC ground Compressor relay pin 30 power HVAC fan low HVAC fan medium HVAC fan high A/C switch compressor relay pin 86 via pressure sw thermostat pressure sw Thermostat to binary pressure switch Binary pressure switch to compressor relay pin 86 HVAC thermostat clean ground

Frame Wiring harness - Electrical schematic frame 17 (A.30.A)

HVAC relay pin 87 output power HVAC keyed power A/C compressor relay pin 87 power HVAC relay fuse power

Connector X-HVC2 (EH) (Mechanical) Cab/HVAC Interconnect to Cab (EH) (Mechanical) Cavity 1 2 3 4 5 6

Circuit ID 935 (BK) 838 (RD) 828 (WH) 827 (WH) 850 (WH) 837 (WH)

7 8

833 (WH) 834 (WH)

9

1012 (BK/ WH) 842 (OR) 143 (OR) 841 (OR) Open 845 (OR)

10 11 12 13 14

Description HVAC ground Compressor relay pin 30 power HVAC fan low HVAC fan medium HVAC fan high A/C switch compressor relay pin 86 via pressure sw thermostat pressure sw Thermostat to binary pressure switch Binary pressure switch to compressor relay pin 86 HVAC thermostat clean ground

Frame Wiring harness - Electrical schematic frame 17 (A.30.A)

HVAC relay pin 87 output power HVAC keyed power A/C compressor relay pin 87 power HVAC relay fuse power

Connector X-HZRDDIODE Hazard Switch Indicator Backfeed Diode to Cab (EH) (Mechanical) Hazard Switch Indicator Backfeed Diode to Cab (EH) (Mechanical) Description Cavity Circuit ID A Hazard sw RH turn signal output 778 (VT) B Hazard sw RH turn signal output 781 (VT) Connector X-K-C1 Connector X-K-C2 Connector X-K-C3 Connector X-K-C4

84522361 15/06/2011

A.30.A / 158

Frame Wiring harness - Electrical schematic frame 16 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 28 - Connector X-NEG_TERM_A to Connector X-POS_TERM_A Connector X-NEG_TERM_A Clean Ground to Chassis (EH) (Mechanical)

RING_TERMINAL

1

Clean Ground to Chassis (EH) (Mechanical) Cavity Circuit ID 1 966 (BK/ Clean ground WH)

Description

Frame Wiring harness - Electrical schematic frame 01 (A.30.A)

Connector X-OILFLT Hydraulic Oil Filter Switch to Chassis (EH) (Mechanical)

SL57_84159852

2

Hydraulic Oil Filter Switch to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 261 (YE) Hydraulic oil filter

84522361 15/06/2011

A.30.A / 159

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-OILTMP Hydraulic Oil Temperature Sender to Chassis (EH) (Mechanical)

SL57_84159852

3

Hydraulic Oil Temperature Sender to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 Hydraulic oil temperature sender 264 (YE)

Frame Wiring harness - Electrical schematic frame 02 (A.30.A)

Connector X-OPT_GND (EH) (Mech)

RING_TERMINAL

4

X-OPT_GND (EH) (Mech) Cavity 1

Circuit ID

Description Ground connection

Frame Wiring harness - Electrical schematic frame 01 (A.30.A)

Connector X-OPT_GND_FRT (EH) (Mech)

RING_TERMINAL

5

84522361 15/06/2011

A.30.A / 160

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

X-OPT_GND_FRT (EH) (Mech) Description Cavity Circuit ID 1 1014 (BK) Ground connection

Frame Wiring harness - Electrical schematic frame 01 (A.30.A)

Connector X-OPT_GND_RR (EH) (Mech)

RING_TERMINAL

6

X-OPT_GND_RR (EH) (Mech) Description Cavity Circuit ID 1 984 (BK) Ground connection

Frame Wiring harness - Electrical schematic frame 01 (A.30.A)

Connector X-OPT_POS-PWR (Mech)

RING_TERMINAL

7

X-OPT_POS-PWR (Mech) Description Cavity Circuit ID 1 Positive connection to battery 119 (RD)

84522361 15/06/2011

A.30.A / 161

Frame Wiring harness - Electrical schematic frame 10 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-PLTLK Pilot Interlock to Chassis (EH)

SL57_87691549

8

Pilot Interlock to Chassis (EH) Description Cavity Circuit ID 1 536 (WH) Loader pilot interlock 2 1063 (BL) Loader pilot interlock ground

Frame Wiring harness - Electrical schematic frame 15 (A.30.A)

Connector X-PORT_LK Port Lock to Chassis (EH) (Mechanical)

SL57_87695582

9

Port Lock to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 304 (WH) Hydraulic loader interlock signal 2 Hydraulic loader interlock ground 957 (BK)

Frame Wiring harness - Electrical schematic frame 15 (A.30.A)

Connector X-POS_TERM_A Battery Power to Chassis (Mechanical)

RING_TERMINAL

10

84522361 15/06/2011

A.30.A / 162

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

X-POS_TERM_A Battery Power to Chassis (Mechanical) Cavity Circuit ID 1 108 (RD) Battery power

Description

84522361 15/06/2011

A.30.A / 163

Frame Wiring harness - Electrical schematic frame 10 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 29 - Connector X-POS_TERM_B to Connector X-UJMR Connector X-POS_TERM_B Battery Power to Chassis (Mechanical)

1

RING TERMINAL

Battery Power to Chassis (Mechanical) Cavity Circuit ID 1 109 (RD) Battery power

Description

Frame Wiring harness - Electrical schematic frame 10 (A.30.A)

Connector X-PRHT Preheat Solenoid to Chassis (EH) (Mechanical)

93109183

2

Preheat Solenoid to Chassis (EH) (Mechanical) Cavity 1 2 3 4 5 6 7 8 9

Circuit ID 641 (WH) 963 (BK) 121 (RD) Open 605 (OR) Open Open Open Open

Description Engine preheat signal Engine preheat relay ground Engine preheat fuse power Engine preheat relay output

84522361 15/06/2011

A.30.A / 164

Frame Wiring harness - Electrical schematic frame 11 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-RDCTRL Ride Control Valve Solenoid to Chassis (EH) (Mechanical)

SL57_87695582

3

Ride Control Valve Solenoid to Chassis (EH) (Mechanical) Description Cavity Circuit ID 1 831 (WH) Ride control valve solenoid signal 2 Ride control valve ground 951 (BK)

Frame Wiring harness - Electrical schematic frame 28 (A.30.A) (EH) Wiring harness - Electrical schematic frame 07 (A.30.A) (Mech)

Connector X-RRJMPRA Chassis/Rear Lamp Jumper Interface to Chassis (EH) (Mechanical)

SL57_87382914

4

Chassis/Rear Lamp Jumper Interface to Chassis (EH) (Mechanical) Cavity 1 2 3 4

Circuit ID 706 (VT) 704 (VT) 703 (VT) 950 (BK)

Description Rear work lamp fuse out Tail lamp splice RH tail lamp fuse out Tail lamp splice LH tail lamp fuse out Rear lamp ground

84522361 15/06/2011

A.30.A / 165

Frame Wiring harness - Electrical schematic frame 08 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector X-TELE Telematics to Chassis (EH) (Mechanical)

SL57_87696550

5

Telematics to Chassis (EH) (Mechanical) Cavity A B C D E F G H J K L M N P R S

Circuit ID 336 (RD) Open 802 (OR) 244 (YE) 308 (YE) Open Open 925 (BK/ WH) Open Open Open 508 (YE) 509 (GN) Open Open Open

Description Telematics unswitched battery

Frame Wiring harness - Electrical schematic frame 30 (A.30.A) (EH) Wiring harness - Electrical schematic frame 26 (A.30.A) (Mech)

Telematics ignition power Alternator lamp telematics engine on Vehicle working condition

Telematics ground

Telematics CAN HI Telematics CAN LO

Connector X-UJML ULM LH to Cab (EH)

SL57_87694583

6

84522361 15/06/2011

A.30.A / 166

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ULM LH to Cab (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12

Circuit ID 215 (RD) 567 (WH) 569 (WH) 1045 (TN) Open Open 218 (OR) 562 (GN) 568 (GN) 1046 (BK) Open Open

LH LH LH LH

Description UB1 X-Y sensor voltage UA1 X sensor output UA1 Y sensor output OV1 X-Y sensor ground

LH LH LH LH

UB2 X-Y sensor voltage UA2 X sensor output UA2 Y sensor output OV2 X-Y sensor ground

Frame Wiring harness - Electrical schematic frame 23 (A.30.A)

Connector X-UJMR UJM RH to Cab (EH)

SL57_87694583

7

UJM RH to Cab (EH) Cavity 1 2 3 4 5 6 7 8 9 10 11 12

Circuit ID 219 (RD) 549 (WH) 561 (WH) 1047 (TN) Open Open 217 (OR) 548 (GN) 560 (GN) 1048 (BK) -

RH RH RH RH

Description UB1 X-Y sensor voltage UA1 X sensor output UA1 Y sensor output OV1 X-Y sensor ground

RH RH RH RH

UB2 X-Y sensor voltage UA2 X sensor output UA2 Y sensor output OV2 X-Y sensor ground

84522361 15/06/2011

A.30.A / 167

Frame Wiring harness - Electrical schematic frame 23 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component identification Engine connectors L223, L225, L230, C227, C232, C238

Connector X-FPT Engine (F5C) to Harness Interconnect

BC08F176-01

1

Harness Interconnect to Engine F5C EXT Cavity 1A 1B 1C 2A 2B 2C 3A 3B 3C 4A 4B 4C 5A 5B 5C 6A

Circuit ID No data No data Open Open No data No data No data No data No data No data No data Open No data No data Open No data

Description EGR valve control signal (PWM) EGR valve control ground (PWM) Not used Not used Boost sensor supply Engine speed sensor A EGR valve position sensor supply Boost temperature signal Engine speed sensor B EGR valve position sensor signal Coolant temperature sensor ground Not used EGR valve position sensor ground Coolant temperature signal Not used Boost sensor ground

6B 6C 7A

Open Open No data

Not used Not used Boost pressure signal

7B 7C 8A 8B 8C

Open Open Open Open Open

Not Not Not Not Not

Frame Wiring harness - Electrical schematic frame 99 (A.30.A)

Wiring harness - Electrical schematic frame 99 (A.30.A)

Wiring harness - Electrical schematic frame 99 (A.30.A) Wiring harness - Electrical schematic frame 99 (A.30.A)

Wiring harness - Electrical schematic frame 99 (A.30.A)

used used used used used

84522361 15/06/2011

A.30.A / 168

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Engine speed sensor

BC08F175-01

2

Engine harness to speed sensor Description Cavity Circuit ID 1 No data Speed sensor supply 2 No data Speed sensor signal 3 Not used Open

Frame Wiring harness - Electrical schematic frame 99 (A.30.A)

EGR valve

BC08F174-01

3

Engine harness to EGR valve Cavity 1 2 3 4 5 6

Circuit ID No data No data Open No data No data No data

Description EGR PWM solenoid supply EGR Potentiometer supply Not used EGR Potentiometer ground EGR PWM solenoid ground EGR Potentiometer signal

84522361 15/06/2011

A.30.A / 169

Frame Wiring harness - Electrical schematic frame 99 (A.30.A) Wiring harness - Electrical schematic frame 99 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Coolant temperature sensor

BC08F173-01

4

Engine harness to coolant temperature sensor Description Cavity Circuit ID A No data Coolant temperature sensor supply B C

Open No data

Frame Wiring harness - Electrical schematic frame 99 (A.30.A)

Not used Coolant temperature sensor signal

Wiring harness - Electrical schematic frame 99 (A.30.A)

Boost pressure/temperature sensor

BC08F172-01

5

Engine harness to boost pressure-temperature sensor Cavity 1 2 3 4

Circuit ID No data No data No data No data

Description Boost sensor ground Boost temperature sensor signal Boost sensor supply Boost pressure sensor signal

84522361 15/06/2011

A.30.A / 170

Frame Wiring harness - Electrical schematic frame 99 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Connector - Component diagram 99 Engine connectors L223, L225, L230, C227, C232, C238

Connector X-FPT Engine (F5C) to Harness Interconnect

BC08F176-01

1

Harness Interconnect to Engine F5C EXT Cavity 1A 1B 1C 2A 2B 2C 3A 3B 3C 4A 4B 4C 5A 5B 5C 6A

Circuit ID No data No data Open Open No data No data No data No data No data No data No data Open No data No data Open No data

Description EGR valve control signal (PWM) EGR valve control ground (PWM) Not used Not used Boost sensor supply Engine speed sensor A EGR valve position sensor supply Boost temperature signal Engine speed sensor B EGR valve position sensor signal Coolant temperature sensor ground Not used EGR valve position sensor ground Coolant temperature signal Not used Boost sensor ground

6B 6C 7A

Open Open No data

Not used Not used Boost pressure signal

7B 7C 8A 8B 8C

Open Open Open Open Open

Not Not Not Not Not

Frame Wiring harness - Electrical schematic frame 99 (A.30.A)

Wiring harness - Electrical schematic frame 99 (A.30.A)

Wiring harness - Electrical schematic frame 99 (A.30.A) Wiring harness - Electrical schematic frame 99 (A.30.A)

Wiring harness - Electrical schematic frame 99 (A.30.A)

used used used used used

84522361 15/06/2011

A.30.A / 171

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Engine speed sensor

BC08F175-01

2

Engine harness to speed sensor Description Cavity Circuit ID 1 No data Speed sensor supply 2 No data Speed sensor signal 3 Not used Open

Frame Wiring harness - Electrical schematic frame 99 (A.30.A)

EGR valve

BC08F174-01

3

Engine harness to EGR valve Cavity 1 2 3 4 5 6

Circuit ID No data No data Open No data No data No data

Description EGR PWM solenoid supply EGR Potentiometer supply Not used EGR Potentiometer ground EGR PWM solenoid ground EGR Potentiometer signal

84522361 15/06/2011

A.30.A / 172

Frame Wiring harness - Electrical schematic frame 99 (A.30.A) Wiring harness - Electrical schematic frame 99 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Coolant temperature sensor

BC08F173-01

4

Engine harness to coolant temperature sensor Description Cavity Circuit ID A No data Coolant temperature sensor supply B C

Open No data

Frame Wiring harness - Electrical schematic frame 99 (A.30.A)

Not used Coolant temperature sensor signal

Wiring harness - Electrical schematic frame 99 (A.30.A)

Boost pressure/temperature sensor

BC08F172-01

5

Engine harness to boost pressure-temperature sensor Cavity 1 2 3 4

Circuit ID No data No data No data No data

Description Boost sensor ground Boost temperature sensor signal Boost sensor supply Boost pressure sensor signal

84522361 15/06/2011

A.30.A / 173

Frame Wiring harness - Electrical schematic frame 99 (A.30.A)

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84522361 15/06/2011

A.30.A / 174

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 01 EH Machines Components/Devices On Frame Component NONE

Connector

Description

Component NONE

84522361 15/06/2011

A.30.A / 175

Connector

Description

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wire Color Codes Abbreviation RD YE GY VT BK/WH

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

84522361 15/06/2011

A.30.A / 176

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR01

1

84522361 15/06/2011

A.30.A / 177

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component NONE

Connector

Description

Component NONE

Connector

Description

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 178

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

SL57_84287890_1

2

84522361 15/06/2011

A.30.A / 179

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 02 EH Machines

Components/Devices On Frame Component B-010

Connector X-OILFLT

S-029

X-101 X-101A X-101B X-OILTMP

B-003

Description Component Hydraulic Filter Restriction Y-318 Switch B-001 STD/On-road Lamp Congifuration

Connector X-318

Description Self Level Valve

X-14

Fuel Level Sender

Hydraulic Oil Temp Sender

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 180

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR02

1

84522361 15/06/2011

A.30.A / 181

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component Y-008

Connector X-BRK

Description Brake Valve Solenoid

Component B-010

Connector X-OILFLT

Y-013

X-CPLR

Y-004

X-HFLO

Y-318

X-318

Hydraulic Coupler Solenoid Self Level Valve

S-029

R-002

X-14

Fuel Level Sender

B-002

X-101 X-101A X-101B X-OILTMP

Description Hydraulic Filter Restriction Switch STD High Flow Solenoid STD/On-Road Lamp Configurator Hydraulic Oil Temperature

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 182

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_02

2

84522361 15/06/2011

A.30.A / 183

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 03 EH Machines

Components/Devices On Frame Component V-004

Connector X-15 X-15-A X-15-B

Description Accessory Backfeed Diode

Component A-001

Connector X-C23

Description Instrument Cluster

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 184

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR03

1

84522361 15/06/2011

A.30.A / 185

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component V-004

Connector X-15

Description Accessory Backfeed Diode

Component A-002

Connector X-C23

Description Instrument Cluster

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 186

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR03

2

84522361 15/06/2011

A.30.A / 187

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 04 EH Machines

Components/Devices On Frame Component Z-2008

Connector None

K-009 K-002 Z-2009

None None None

V-007

X-316

Description Main Power Distribution Fuse Block #1 Main Power Relay Lights Relay #2 Main Power Distribution Fuse Block #1 Ignition Backfeed Diode

Component K-007

Connector None

Description Crank Relay

K-001 K-018 H-002

None None X-BKUP-PWR X-BKUP-GND

Lights Relay #1 Accessory Relay Backup Alarm

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 188

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR04

1

84522361 15/06/2011

A.30.A / 189

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component Z-2008

Connector None

K-009 K-002 Z-2009

None None None

S-005

X-43

Description Main Power Distribution Fuse Block #1 Main Power Relay Lights Relay #2 Main Power Distribution Fuse Block #2 Mechanical Backup Switch #2

Component K-007

Connector None

Description Crank Relay

K-001 K-018 S-004

None None X-42

H-002

X-BKUP-PWR X-BKUP-GND

Lights Relay #1 Accessory Relay Mechanical Backup Switch #1 Backup Alarm

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 190

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR04

2

84522361 15/06/2011

A.30.A / 191

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 05 EH Machines

Components/Devices On Frame Component Z-FUSE2

Connector None

K-019

None

Description Accessory Power Distribution Fuse Block 2 Option Relay

Component K-017

Connector None

Description Front Electric Relay

K-003

None

UCM Power Relay

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 192

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR05

1

84522361 15/06/2011

A.30.A / 193

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component Z-FUSE2

Connector None

K-019

None

Description Accessory Power Distribution Option Relay

S-037

X-163 X-164

Mechanical Brake Pressure Switch

Component K-017

Connector None

Description Front Electric Relay

S-036

X-161 X-162

Mechanical Brake Pressure Switch

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 194

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR05

2

84522361 15/06/2011

A.30.A / 195

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 06 EH Machines

Components/Devices On Frame Component S-009 S-013 Z-008 S-041 S-010

Connector X-300 X-317 X-ACC X-302 X-304

Description Hydraulic Coupler Switch Self Level Switch Accessory Power Outlet Hazard Lamp Switch Electrical Auxiliary Hydraulic ON/OFF Switch (Handle)

Component S-001 S-011 S-005 S-042

Connector X-301 X-365 X-306 X-303

Description Rotating Beacon Switch NH Park Brake Switch Loader Lockout Switch High Flow Switch

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 196

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR06

1

84522361 15/06/2011

A.30.A / 197

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component S-009

Connector X-300

Description Hydraulic Coupler Switch

S-013 Z-008 S-040 S-038

X-317 X-ACC X-302 X-304

Self Level Switch S-007 Accessory Power Outlet S-005 Hazard Lamp Switch S-039 Electrical Auxiliary Hydraulic ON/OFF Switch (Handle)

Component S-001

Connector X-301 X-365 X-306 X-303

Description Rotating Beacon/Strobe Switch NH Park Brake Switch Loader Lockout Switch High Flow Switch

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 198

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR06

2

84522361 15/06/2011

A.30.A / 199

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 07 EH Machine

Components/Devices On Frame Component Z-012 S-022 S-014 S-033

Connector None X-403 X-406 X-408

S-015 S-024 Y-005

X-408 X-408 X-2SPD

Description Right-hand Control Handle #2 UP / DN Park Brake Switch Turn Signal Switch - Left / Right #2 UP / DN 2SPD 2 Speed Solenoid

Component S-031 S-018 Z-005 S-033

Connector X-403 X-406 None X-408

S-032 S-023

X-408 X-408

Description #1 UP / DN Ride Control/Glide Ride Left-hand Control Handle 2ND AUX HYD - EXT (UP) / RET (DN) #3 UP / DN Horn

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 200

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR07

1

84522361 15/06/2011

A.30.A / 201

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component S-031 S-014 S-033 S-023 H-009

Connector X-404 None None None X-HORN-PWR X-HORN-GND

Description RH Control Handle Park Brake Switch 2ND AUX HYD Horn Horn

Component S-018 S-027 S-024 Y-010 Y-005

Connector X-402 X-407 X-405 X-RDCTRL X-2SPD

Description Ride Control/Glide Ride Turn Signal 2SPD Ride Control Solenoid 2 Speed Solenoid

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 202

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR07

2

84522361 15/06/2011

A.30.A / 203

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 08 EH Machines

Components/Devices On Frame Component S-012 E-023 E-024 NONE E-022 E-033

Connector X-311 X-344 X-343 X-85 X-178 X-34

Description Lamp Selector Switch LH Front Strobe RH Front Strobe RH DIA Side Lamp Rotating Beacon LH Rear Work

Component J-001 E-021 E-025 NONE E-038

Connector X-77 X-341 X-342 X-86 X-35

Description Side Lamp DIA Socket LH Rear Strobe RH Rear Strobe LH DIA Side Lamp RH Rear Work

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 204

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR08

1

84522361 15/06/2011

A.30.A / 205

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component S-012 E-023 E-024 E-003

Connector X-311 X-344 X-343 X-97

Description Lamp Selector Switch LH Front Strobe RH Front Strobe Dome Lamp

Component U-005 E-021 E-025

Connector X-77 X-341 X-342

Description Side Lamp DIA Socket LH Rear Strobe RH Rear Strobe

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 206

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR08

2

84522361 15/06/2011

A.30.A / 207

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 09 EH Machines

Components/Devices On Frame Component M-506 S-038 Z-014

Connector X-506 X-505 X-502A

Description Component Front Door Washer Pump S-016 Z-010 Door Switch Rear Wiper Motor

Connector X-503 X-502

Description Wiper/Washer Switch Door Wiper Motor

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 208

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR09

1

84522361 15/06/2011

A.30.A / 209

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component M-506

Connector X-506

S-041 M-007

X-505 X-502A

Description Component Front Door Washer Pump S-041 (Cab) M-001 Door Switch Rear Window Wiper Motor

Connector X-503

Description Wiper/Washer Switch

X-502

Door Wiper Motor

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 210

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR09

2

84522361 15/06/2011

A.30.A / 211

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 10 EH Machines

Components/Devices On Frame Component M-506

Connector X-506

S-041 M-007

X-505 X-502A

Description Component Front Door Washer Pump S-041 (Cab) M-001 Door Switch Rear Window Wiper Motor

Connector X-503

Description Wiper/Washer Switch

X-502

Door Wiper Motor

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 212

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR10

1

84522361 15/06/2011

A.30.A / 213

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component M-506

Connector X-506

S-041 M-007

X-505 X-502A

Description Component Front Door Washer Pump S-041 (Cab) M-001 Door Switch Rear Window Wiper Motor

Connector X-503

Description Wiper/Washer Switch

X-502

Door Wiper Motor

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 214

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR10

2

84522361 15/06/2011

A.30.A / 215

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 11 EH Machines

Components/Devices On Frame Component M-506

Connector X-506

S-041 M-007

X-505 X-502A

Description Component Front Door Washer Pump S-041 (Cab) M-001 Door Switch Rear Window Wiper Motor

Connector X-503

Description Wiper/Washer Switch

X-502

Door Wiper Motor

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 216

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR11

1

84522361 15/06/2011

A.30.A / 217

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component M-506

Connector X-506

S-041 M-007

X-505 X-502A

Description Component Front Door Washer Pump S-041 (Cab) M-001 Door Switch Rear Window Wiper Motor

Connector X-503

Description Wiper/Washer Switch

X-502

Door Wiper Motor

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 218

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR11

2

84522361 15/06/2011

A.30.A / 219

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 12 L223, L225, L230, C227, C232, C238EH

F5C Machines

Components/Devices On Frame Component B-016

Connector X-AIRFLT

Description Component Air Filter Restriction Switch B-017 NONE

X-FUEL

Description Engine Oil Pressure Switch Fuel Solenoid

B-004

X-504

G-026

X-5

Engine Coolant Temperature Sender Alternator

M-008

X-C126

Starter Motor

Connector X-510

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 220

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR12

1

84522361 15/06/2011

A.30.A / 221

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical F5C Machines

Components/Devices On Frame Component B-016

Connector X-AIRFLT

Description Component Air Filter Restriction Switch B-017 NONE

X-FUEL

Description Engine Oil Pressure Switch Fuel Solenoid

B-004

X-504

G-026

X-5

Engine Coolant Temperature Sender Alternator

M-008

X-C126

Starter Motor

Connector X-510

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 222

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR12

2

84522361 15/06/2011

A.30.A / 223

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 13 L213, L215, L218, L220EH

ISM Machines

Components/Devices On Frame Component B-028

Connector X-508

Description Component Air Filter Restriction Switch B-027 NONE

X-517

Description Engine Oil Pressure Switch Fuel Solenoid

B-012

X-516

G-027

X-5

Engine Coolant Temperature Sender Alternator

NONE

X-513

Starter

Connector X-512

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 224

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR13

1

84522361 15/06/2011

A.30.A / 225

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical ISM Machines

Components/Devices On Frame Component B-028

Connector X-508

Description Component Air Filter Restriction Switch B-027 NONE

X-517

Description Engine Oil Pressure Switch Fuel Solenoid

B-012

X-516

G-027

X-5

Engine Coolant Temperature Sender Alternator

NONE

X-513

Starter

Connector X-512

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 226

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR13

2

84522361 15/06/2011

A.30.A / 227

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 14 EH Machines

Components/Devices On Frame Component S-003 Z-2011

Connector X-9 X-155B X-156B X-157B

Description Ignition Switch Turn Signal Indicator

Component Z-004

Connector X-310

Description 2 Speed Indicator

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 228

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR14

1

84522361 15/06/2011

A.30.A / 229

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component S-003 Z-2011

Connector X-9 X-310

Description Ignition Switch Turn Signal Indicator

Component E-008

Connector X-310

Description 2 Speed Indicator

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 230

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR14

2

84522361 15/06/2011

A.30.A / 231

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 15 EH Machines

Components/Devices On Frame Component NONE NONE

Connector X-AUX_EXT X-PORT_LK

Description 2ND AUX Extend Loader Port Lock

Component NONE NONE

Connector X-AUX_RET X-PLTLK

Description 2ND AUX Retract Loader Pilot Interlock

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 232

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR15

1

84522361 15/06/2011

A.30.A / 233

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component NONE

Connector X-410

NONE

X-PORT_LK

Description (Chassis Option) Interconnector Loader Lock Port Lock

Component NONE

Connector X-412

Description (Chassis Option) Port Lock Port Lock Valve Connector

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 234

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR15

2

84522361 15/06/2011

A.30.A / 235

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Components/Devices On Frame

Wiring harness - Electrical schematic frame 16 L213 WE, L215 WE, L218 WE, L220 WE, L223 WE, L225 WE, L230 WE, C227 WE, C232 WE, C238 WEEH

EU Machines

Component V-010 Z-013 NONE NONE NONE NONE

Description Connector X-HZRDDIODE Hazard Switch Indicator Backfeed Diode X-411 Flasher Module X-31 LH Side Lamp X-31 LH Cab Lamps GND X-30 RH Cab Turn Signal X-30 RH Cab Lamps GND

Component S-034

Connector X-CTS

Description Turn Signal Switch

NONE NONE NONE NONE

X-31 X-31 X-30 X-30

LH Cab Turn Sign LH Work Lamp RH Work Lamp PW RH Side Lamp PWR

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 236

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR16

1

84522361 15/06/2011

A.30.A / 237

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical EU Machines

Components/Devices On Frame Component V-010 Z-013 NONE NONE NONE NONE

Connector X-HZRD X-411 X-31 X-31 X-30 X-30

Description 6A Diode Flasher Module LH Side Lamp LH Cab Lamps GND RH Cab Turn Signal RH Cab Lamps GND

Component S-034 NONE NONE NONE NONE

Connector X-CTS X-31 X-31 X-30 X-30

Description Turn Signal Switch LH Cab Turn Signal LH Work Lamp RH Work Lamp PWR RH Side Lamp PWR

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 238

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR16

2

84522361 15/06/2011

A.30.A / 239

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 17 EH Machines

Components/Devices On Frame Description HVAC Box

Component Z-018

Connector X-AC_COMP

Description A/C Compressor

K-020

Connector X-HVC1 X-HVC2 X-111

Condenser Relay

Z-017

X-252

Z-019

X-271

Water Valve

S-020

X-270

S-017

X-275

AC Switch (Left Console)

S-042

X-76

Temp Control (LH Console) Blower Switch (Left Console) HVAC High Pressure Switch

Component A-003

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 240

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR17

1

84522361 15/06/2011

A.30.A / 241

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Description Turn Signal Indicator

Component NONE

Connector X-74

Description HVAC Condenser Fan

K-003

Connector X-HVC1 X-HVC2 X-111

Condenser Relay

Z-017

X-252

Z-019

X-271

Water Valve

S-020

X-270

S-017

X-275

AC Switch (Left Console)

S-042

X-76

Temp Control (LH Console) Blower Switch (Left Console) HVAC High Pressure Switch

Z-018

X-AC_COMP

A/C Compressor

Component HVAC BOX

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 242

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR17

2

84522361 15/06/2011

A.30.A / 243

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 18 EH Machines

Components/Devices On Frame Component NONE NONE NONE NONE E-038 NONE E-027 NONE E-017 NONE E-44 E-019

Connector X-200 X-200 X-200 X-37 X-37 X-228 X-228 X-229 X-229 X-196 X-196 X-80 X-81

Description LH Rear Turn Sig LH Rear Position Brake Lamp Signa LH Rear Road Lamp Brake Lamp LH Front Road Lamp Position Lamp RH Front Road Lamp Position Lamp RH Rear Road Lamp Brake Lamp License Plate

Component NONE NONE NONE E-037 E-198 E-012 E-028 E-011 E-018 E-196 E-44

Connector X-200 X-200 X-200 X-37 X-37 X-228 X-228 X-229 X-229 X-196 X-196

Description RH Rear Turn Sig RH Rear Position Rear Lamps Gnd Position Lamp Turn Signal Low Beam Turn Signal Low Beam Turn Signal Turn Signal Position Lamp

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 244

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR18

1

84522361 15/06/2011

A.30.A / 245

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component NONE NONE NONE Z-009 E-037 Z-001 E-027 Z-002 E-017 Z-011 E-44

Connector X-200 X-200 X-200 X-37 X-37 X-228 X-228 X-229 X-229 X-196 X-196

Description LH Rear Turn Signal LH Rear Position Brake Lamp Signal LH Rear Road Lamp Brake LH Front Road Lamp Position Lamp RH Front Road Lamp Position Lamp RH Rear Road Lamp Brake

Component NONE NONE NONE E-037 E-198 E-012 E-028 E-011 E-018 E-196 E-44

Connector X-200 X-200 X-200 X-37 X-37 X-228 X-228 X-229 X-229 X-196 X-196

Description RH Rear Turn Signal RH Rear Position Rear Lamps Gnd Position Turn Signal Low Beam Turn Signal Low Beam Turn Signal Turn Signal Position

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 246

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR18

2

84522361 15/06/2011

A.30.A / 247

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 19 EH Machines

Components/Devices On Frame Component U-001 S-037

Connector X-403 X-403

Description Component Right-hand Control Handle S-036 None S-007

Connector X-403 X-403

Description Proportional AUX Switch Float Switch

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 248

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR19

1

84522361 15/06/2011

A.30.A / 249

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component U-001

Connector X-430

Description EH AUX PWM Controller

Y-003

X-433

Proportional AUX Valve Extend

Component Y-002

Connector X-432

Description Proportional AUX Valve Retract

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 250

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR19

2

84522361 15/06/2011

A.30.A / 251

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 20 EH Machines

Components/Devices On Frame Component NONE R-001 S-043 V-009

Connector X-58 X-58A X-58 X-58A X-104 X-98

Description Seat

Component S-003

Seat Heat Element

S-002

Operator Restraint Switch V-005 EH Seat SW UCM Diode V-006

Connector X-58 X-58A X-58 X-58A X-99 X-298

Description Seat Heat Switch Seat Switch EH Lap Bar Diode EH UCM Wakeup Diode

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 252

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR20

1

84522361 15/06/2011

A.30.A / 253

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component Z-006 R-001 S-011

Connector X-58 X-58A X-58 X-58A X-104

Description Seat

Component S-003

Seat Heat Element

S-002

Connector X-58 X-58A X-58 X-58A

Description Seat Heat Switch Seat Switch

Operator Restraint Switch

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 254

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR20

2

84522361 15/06/2011

A.30.A / 255

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 21 EH Machines

Components/Devices On Frame Component H-011 NONE NONE NONE NONE

Connector X-330 X-331 X-97 X-335 X-335 X-335

Description RH Speaker

Component H-012

Lap Bar Switch Ground Right Speaker (-) Left Speaker (-)

NONE NONE NONE

Connector X-332 X-333 X-335 X-335 X-335

Description LH Speaker Power Left Speaker (+) Right Speaker (+)

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 256

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR21

1

84522361 15/06/2011

A.30.A / 257

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component H-011 NONE NONE NONE NONE

Connector X-330 X-331 X-335 X-335 X-335 X-335

Description RH Speaker

Component H-012

Radio Connector Ground Right Speaker (-) Left Speaker (-)

NONE NONE NONE

Connector X-332 X-333 X-335 X-335 X-335

Description LH Speaker 12 Power Left Speaker (+) Right Speaker (+)

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 258

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR21

2

84522361 15/06/2011

A.30.A / 259

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 22 L223, L225, L230, C227, C232, C238

Components/Devices On Frame Component Y-017 NONE

Connector X-K-C4 X-K-C3

Description Stop (Fuel Solenoid) KSB Signal

Component NONE B-015

Connector X-K-C2 X-K-C1

Description Interface Water Temperature Sensor

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 260

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR22

1

84522361 15/06/2011

A.30.A / 261

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 23 EH Machines

Components/Devices On Frame Component NONE

Connector

Description

Component NONE

Connector

Description

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 262

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR23

1

84522361 15/06/2011

A.30.A / 263

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component U-004

Connector X-402

Description Component Right-hand Control Handle NONE

Connector X-402

Description Proportional Auxiliary Hydraulic Switch

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 264

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR23

2

84522361 15/06/2011

A.30.A / 265

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 24 EH Machines

Components/Devices On Frame Component Y-003 Y-007 Y-012

Connector X-25 X-27 X-29

NONE

X-23

NONE

X-22

Description Bucket Valve Retract Loader Valve Retract Proportional AUX Valve Retract Auxiliary Spool Position Sensor Boom Spool Position Sensor

Component Y-006 Y-009 Y-011

Connector X-26 X-28 X-24

NONE

X-21

Description Bucket Valve Extend Loader Valve Extend Proportional AUX Valve Extend Bucket Spool Position Sensor

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 266

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR24

1

84522361 15/06/2011

A.30.A / 267

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component NONE

Connector X-107

Description Multifunction Attachment Connector

Component NONE

Connector X-86

Description Multifunction Water Pump

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 268

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR24

2

84522361 15/06/2011

A.30.A / 269

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 25 EH Machines

Components/Devices On Frame Component Y-013

Connector X-CPLR

NONE

X-20

Description Hydraulic Coupler Solenoid Throttle Position Sensor

Component Y-004

Connector X-HFLO

Description STD High Flow Solenoid

NONE

X-10

Chassis / Loader Interface

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 270

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR25

1

84522361 15/06/2011

A.30.A / 271

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machinews

Components/Devices On Frame Component NONE

Connector X-DIAG

Description CAN Diagnostic Connector

Component

Connector

Description

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 272

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR25

2

84522361 15/06/2011

A.30.A / 273

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 26 EH Machines

Components/Devices On Frame Component A-002

Connector X-CN1A X-CN1B X-CN2A X-CN2B X-CN3A X-CN4A X-CN3B

Description

Component

Connector

Description

UCM

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 274

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR26

1

84522361 15/06/2011

A.30.A / 275

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component NONE

Connector X-150 X-TELE

Description CAN 120 OHM Termination Resistor

Component

Connector

Description

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 276

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR26

2

84522361 15/06/2011

A.30.A / 277

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 27 EH Machines

Components/Devices On Frame Component NONE

Connector X-94

NONE NONE

X-18 X-17

Description Component NONE LH Pump Swash Plate Sensor Right Drive Pump Reverse NONE RH Drive Pump Forward NONE

Connector X-93 X-16 X-13

Description RH Pump Swash Plate Sensor Left Drive Pump Reverse Left Drive Pump Forward

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 278

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR26

1

84522361 15/06/2011

A.30.A / 279

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines

Components/Devices On Frame Component NONE

Connector

Description

Component NONE

Connector

Description

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 280

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84287890_FR27

2

84522361 15/06/2011

A.30.A / 281

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Components/Devices On Frame

Wiring harness - Electrical schematic frame 28 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controlsEH

Machines

Component Y-010 B-009

Connector X-RDCTRL X-CHGPRS

Description Ride Control Solenoid Charge Pressure Switch

Component Y-008 S-039

Connector X-BRK X-BRKPRS

Description Brake Valve Solenoid Brake Pressure Switch

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 282

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR28

1

84522361 15/06/2011

A.30.A / 283

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Components/Devices On Frame

Wiring harness - Electrical schematic frame 29 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls,

Component NONE

Connector X-107

L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controlsEH

Machines

Description Multifunction Attachment Connector

Component NONE

Connector X-66

Description Multifunction Water Pump

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 284

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR29

1

84522361 15/06/2011

A.30.A / 285

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Components/Devices On Frame

Wiring harness - Electrical schematic frame 30 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls,

Component NONE

Connector X-TELE

Description Telematics Connector

Component

Connector

Description

L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controlsEH

Machines

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 286

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR30

1

84522361 15/06/2011

A.30.A / 287

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Components/Devices On Frame

Wiring harness - Electrical schematic frame 31 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls,

Component NONE

Connector X-DIAG

L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controlsEH

Machines

Description CAN Diagnostic Connector

Component

Connector

Description

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 288

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR31

1

84522361 15/06/2011

A.30.A / 289

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Components/Devices On Frame

Wiring harness - Electrical schematic frame 32 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controlsEH

Machine

Component NONE NONE

Connector X-19 X-67

Description Component EHF Extend NONE EHF Pressure Transducer

Connector X-40

Description EHF Retract

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 290

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR32

1

84522361 15/06/2011

A.30.A / 291

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Components/Devices On Frame

Wiring harness - Electrical schematic frame 33 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls,

Component NONE

L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controlsEH

Machines

Connector X-108 X-109 X-110 X-112 X-113 X-401

Description

Component

Connector

Description

Wire Color Codes Abbreviation RD YE GY VT BK/WH

84522361 15/06/2011

A.30.A / 292

Color Red Yellow Grey Violet Black/White

Abbreviation TN BK OR BL LG

Color Tan Black Orange Blue Light Green

Abbreviation WH GN PK LB

Color White Green Pink Light Blue

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

87673075_FR33

1

84522361 15/06/2011

A.30.A / 293

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Electrical schematic frame 99 L223, L225, L230, C227, C232, C238

F5C engine harness Components/Devices On Frame Component (1)

Connector X-FPT

(2)

Coolant temperature sensor

(3)

EGR valve

84522361 15/06/2011

A.30.A / 294

Description FPT engine harness to connector X-FPT Coolant temperature sensor

EGR valve

Component (4) (5)

Connector Engine speed sensor Boost pressure/ temperature sensor

Description Engine speed sensor Boost air pressure/ temperature sensor

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

F5CEGRT3

1

84522361 15/06/2011

A.30.A / 295

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Detailed view Harness Overview EH Machines 1 2

Lap Bar Switch Radio Connector

18 19

3

Left Speaker

20

4 5 6 7

21 22 23 24

10

Cab / Dome Lamp Jumper Engine Harness UJM LH Cab / RH Lamp Jumper Interface LH Handle Interconnect Cab / LH Lamp Jumper Interface Cab / Seat Interface

11 12 13

2nd Aux Extend Water Valve Throttle Position Sensor

28 29 30

14

High Flow Valve Solenoid

31

15 16

LH Pump Swash Plate Sensor 32 33 RH Pump Swash Plate Sensor 34 Chassis / Loader Interface

8 9

17

84522361 15/06/2011

A.30.A / 296

25 26 27

Self Level Valve RH Handle Interconnect Park Brake / Ride Ctrl RH Handle Interconnect FE / Proportional Aux / Float UJM RH Front Door Washer Pump Glow Plug FPT Interface Chassis Option / RH Boom Lights Interconnect Backup Alarm Fuel Level Sender Chassis / Rear Lamp Jumper Interface HVAC Condenser Fan Beacon Lamp Socket Chassis Options / Multifunction Interconnect Chassis Options / LH Boom Lights Interconnect Right Speaker Horn Ground Horn Power

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

CNH_EH842

1

84522361 15/06/2011

A.30.A / 297

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Mechanical Machines 1

Right Speaker

26

2 3

Right Speaker Left Speaker

27 28

4 5 6 7

Left Speaker Cab / Dome Lamp Jumper Condenser Relay [Cab] Cab / RH Lamp Jumper Interface Cab / LH Lamp Jumper Interface Chassis / Engine Harness Telematics Interconnect Accessory Power Outlet

29 30 31 32

CAN 120 Ohm Termination Resistor Engine Harness Ride Control Valve Solenoid Rdctrl Self Level Valve Front Washer Pump CAB / HVAC Interconnect Glow Plug FPT Interface

33

Fuel Level Sender

34

Backup Alarm

35 36 37 38 39 40 41 42 43 44 45 46

Chassis / Rear Lamp Jumper Interface Side Lamp DIA Socket HVAC Condenser Fan Rear Window Wiper Motor Beacon Lamp Socket Hydraulic Oil Filter Switch Preheat Fuse Horn Power Horn Ground Lap Bar Sw Radio Connector Cab / Chassis 3

47 48

Cab / Chassis 2 Cab / Chassis 1

49 50

Can / Seat Interface Port Lock

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

84522361 15/06/2011

A.30.A / 298

Cab / Door Switch Interface Mechanical Backup Switch #1 Power Distribution Chassis Water Valve Brake Valve Solenoid 2 Speed Valve Solenoid CAN Diagnostic Connector Door Wiper Motor Cab / Chassis Options 2 Cab / Chassis Options 1 Hydraulic Oil Temperature Sender Telematics RH Handle Interconnect Park Brake / Ride Control EH Aux PWM Controller LH Handle Interconnect Horn / Two Speed

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

CNH_MECH84

2

84522361 15/06/2011

A.30.A / 299

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

84522361 15/06/2011

A.30.A / 300

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Sensing system - Overview Temperature sensors

1z0o2004112136

1

Temperature sensors most generally incorporate a thermistor. A thermistor is a resistor that changes its resistance according to 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 type is often used by sensors that indicate temperature change in fluids, like those contained in a hydraulic reservoir or in the engine coolant system. Often the signal provided to the controller is used by the controller to provide information to a display device which could display actual values or operate a warning indicator.

84522361 15/06/2011

A.30.A / 301

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Sensing system - Overview Speed and position sensors Most of the speed and position sensors used are 2 and 3-wire active devices (requires an electrical source to function). Therefore, a source and ground are supplied to the sensor. Non-contact sensing of a target (ferrous material) is performed by the sensor in different ways, generally electro-magnetic coupling, which affects the source (typically a switch like affect, from one level to another). The altered source may or may not be conditioned by the sensor. The controller monitoring the sensor uses the sensor signal (affected source) to produce on and off signals for digital processing. For speed sensing this would relate to how many pulses (off to on or on to off transitions) during an established period of time and for position sensing the level of the signal (on or off). These sensors can not be effectively checked out-of-circuit with only a DVOM. If the sensor is faulty and the sensor circuit is complete, use the diagnostic capability of the display monitor to test the sensor functionality in the circuit.

40011026

1

Sensor Adjustment When installing a new sensor, adjust the sensor to obtain a clearance of 3 mm (1/8 in) to the target metal.

84522361 15/06/2011

A.30.A / 302

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Electrical test Open Circuit Prior operation: Up to three electrical test may be required to properly troubleshoot electrical concerns. The other two tests are: Short to Ground - refer to ELECTRICAL POWER SYSTEM - Electrical test Short to Ground (A.30.A). Short to Voltage - refer to ELECTRICAL POWER SYSTEM - Electrical test Short to Voltage (A.30.A). Each test is described in detail. Ensure that all steps are reviewed and followed when testing. 1.

Key switch OFF (sometimes battery disconnected or fuse pulled out if specified in procedure).

2.

Connectors at both ends of the circuit disconnected. All other connectors must be reconnected to perform test.

84522361 15/06/2011

A.30.A / 303

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

3.

Set meter to measure resistance or ohms, and measure circuit resistance as illustrated. Use the red meter lead (1) to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. Use the black lead (2) to make contact with the connector pin at the other end of the circuit. Avoid contact with other pins in the connector and the connector case, if it is metal.

NOTE: Testing continuity from one connector to another is often not possible given the distance between the connectors. The alternate method used in this service manual requires the use of a jumper wire. Attach the jumper wire between the specified pin in one of the connectors and chassis (frame) ground. Use the red lead of the multi-meter to touch the specified pin of the other connector and touch the black lead to chassis (frame) ground. Using chassis (frame) ground as an integral part of the continuity test requires good electrical contact with the metal frame (chassis). Paint and contaminants serve as insulators and reduce the effectiveness of the electrical connection. If possible use frame (chassis) ground points already established for the black lead and one end of the jumper wire.

26093637

4.

Determine if measured resistance falls within guidelines specified in the procedure. If the resistance is no more than 3 - 4 ohms, the circuit is continuous. More resistance usually indicates dirty or corroded terminals in connectors, and 100k ohms or greater indicates an open circuit.

84522361 15/06/2011

A.30.A / 304

1

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Electrical test Short to Voltage Prior operation: Up to three electrical test may be required to properly troubleshoot electrical concerns. The other two tests are: Short to Ground - refer to ELECTRICAL POWER SYSTEM - Electrical test Short to Ground (A.30.A). Open Circuit - refer to ELECTRICAL POWER SYSTEM - Electrical test Open Circuit (A.30.A). Each test is described in detail. Ensure that all steps are reviewed and followed when testing. 1.

Key switch ON (sometimes OFF, if specified in procedure).

2.

Connectors at sensor, switch or potentiometer end disconnected. All other connectors must be reconnected to perform test (unless otherwise specified in the procedure).

84522361 15/06/2011

A.30.A / 305

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

3.

Set meter to measure DC VOLTS, and measure circuit voltage as illustrated. Use the red meter (1) lead to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. Use the black lead (2) to make contact with a plated metal part on the chassis such as a jump start post if fitted. Make sure the surface of the part is not corroded.

26093640

4.

Determine if measured voltage falls within guidelines specified in the procedure.

84522361 15/06/2011

A.30.A / 306

1

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Electrical test Short to Ground Prior operation: Up to three electrical tests may be required to properly troubleshoot electrical concerns. The other two tests are: Short to Voltage - refer to ELECTRICAL POWER SYSTEM - Electrical test Short to Voltage (A.30.A). Open Circuit - refer to ELECTRICAL POWER SYSTEM - Electrical test Open Circuit (A.30.A). Each test is described in detail. Ensure that all steps are reviewed and followed when testing. 1.

Key switched power OFF, (sometimes battery disconnected or fuse pulled out if specified in procedure).

2.

Connectors at each end or ends of circuit disconnected to prevent false readings.

84522361 15/06/2011

A.30.A / 307

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

3.

Set meter to measure resistance or ohms, and measure circuit resistance. Use black lead (2) to make contact with a plated metal part on the chassis such as a jump start post if fitted. Make sure the surface of the part is not corroded. Use the red meter lead (1) to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors.

26093638

84522361 15/06/2011

A.30.A / 308

1

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

4.

Determine if measured resistance falls within guidelines specified in the procedure. A reading of less than 3 - 4 ohms indicates a direct short to chassis ground and must be located and repaired. Higher resistances usually indicate circuit paths through modules, and that an additional connector needs to be disconnected to perform the test. More than 100k ohms indicates that the circuit is free of shorts to ground.

NOTE: All of the output and many of the input devices used in the electrical / electronic system use a reference or chassis ground as a functional part of the control system. Therefore, it is important to remove this intended circuit ground before testing for a "Short to Ground"

84522361 15/06/2011

A.30.A / 309

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Battery - Check Maintenance Free During normal use of a vehicle the battery is constantly being discharged, and recharged by the vehicle electrical systems. This process causes evaporation of the battery electrolyte. Maintenance free batteries have condenser channels that allow the gases to condense into liquids again. This prevents the gases from escaping through vent holes so there is no requirement to top off the electrolyte. The following procedure will tell if a battery is fit for service or if it must be replaced. 1.

Inspect the battery before testing. Many conditions can be seen and corrected before battery problems occur. Inspect the battery case for cracks and leaks. Inspect the battery posts, cables and clamps for broken wires, loose connections and corrosion. Make sure the top of the battery is clean and dry. Dirt or electrolyte on top of a battery can cause the battery to discharge. This material on the top of a battery provides a path for current to flow, permitting the battery to discharge.

2.

Remove the battery from the vehicle. Clean the outside of the battery. Also, clean the battery tray. When cleaning a battery, use a solution of baking soda and water. Check and clean the battery cables if necessary.

3.

Check the battery carrier to make sure the carrier is in good condition. Check the battery brackets for the correct tension. A loose battery bracket will allow the battery to vibrate. Vibration will damage the battery. Battery brackets which are too tight can buckle or crack the battery case.

4.

Check the battery for raised cell covers or a warped case. This may indicate that the battery has been overheated or overcharged.

5.

Using a multi-meter check the battery voltage. A reading of less than 11.6 volts indicates the battery should be charged using a battery charger. If battery voltage is unable to be raised to approximately 12.4 volts, the battery should be replaced.

84522361 15/06/2011

A.30.A / 310

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Battery - Remove WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

WARNING Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply could result in death or serious injury. W0006A

WARNING Chemical hazard! When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spill through the vent caps. Lift a plastic-cased battery with a battery carrier or with your hands positioned on opposite corners of the battery. Always wash your hands after handling. Failure to comply could result in death or serious injury. W0385A

Battery removal 1.

Remove battery cover hardware (1) and battery cover (2).

931001637

1

931001638

2

NOTE: NEW HOLLAND CONSTRUCTION Battery disconnect is optional. 2.

Turn battery quick disconnect, if equipped (1) to the off position, (2) as shown.

84522361 15/06/2011

A.30.A / 311

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

3.

4.

5.

6.

Disconnect negative cable connection (1).

931001641

3

931002054

4

931001639

5

931001642

6

Disconnect positive cable connection (1).

Loosen nuts (1) and remove battery hold down (2).

Remove battery (1) in direction of arrow.

84522361 15/06/2011

A.30.A / 312

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Battery - Install WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

WARNING Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply could result in death or serious injury. W0006A

WARNING Chemical hazard! When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spill through the vent caps. Lift a plastic-cased battery with a battery carrier or with your hands positioned on opposite corners of the battery. Always wash your hands after handling. Failure to comply could result in death or serious injury. W0385A

NOTE: NEW HOLLAND CONSTRUCTION Battery disconnect is optional.

Battery installation 1.

2.

Confirm battery quick disconnect (1) is in the off position (2), as shown.

931001638

1

931001642

2

Place battery (1) in compartment, in direction of arrow.

84522361 15/06/2011

A.30.A / 313

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

3.

4.

5.

6.

Install battery hold down (1) and secure with nuts (2).

931001640

3

931001639

4

931002054

5

931001641

6

Insure the hold down (1) is square to the battery (2).

Connect positive cable connection (1).

Connect negative cable connection (1).

84522361 15/06/2011

A.30.A / 314

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

NOTE: NEW HOLLAND CONSTRUCTION Battery disconnect is optional. 7.

8.

Turn battery quick disconnect (1) to the on position (2) as shown.

931001828

7

931001637

8

Install battery cover (1) and secure with hardware (2).

84522361 15/06/2011

A.30.A / 315

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Battery - Disconnect WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

WARNING Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply could result in death or serious injury. W0006A

WARNING Chemical hazard! When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spill through the vent caps. Lift a plastic-cased battery with a battery carrier or with your hands positioned on opposite corners of the battery. Always wash your hands after handling. Failure to comply could result in death or serious injury. W0385A

Disconnect battery 1.

Remove battery access cover (1) by removing the three mounting bolts (2).

931001637

1

931001638

2

NOTE: NEW HOLLAND CONSTRUCTION Battery disconnect is optional. 2.

Turn battery disconnect (1), if equipped, to the off position (2).

84522361 15/06/2011

A.30.A / 316

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

3.

4.

Disconnect negative battery cable connection (1).

931001641

3

931002054

4

Disconnect positive battery connection (1).

84522361 15/06/2011

A.30.A / 317

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Battery - Connect WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

WARNING Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply could result in death or serious injury. W0006A

WARNING Chemical hazard! When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spill through the vent caps. Lift a plastic-cased battery with a battery carrier or with your hands positioned on opposite corners of the battery. Always wash your hands after handling. Failure to comply could result in death or serious injury. W0385A

Connect battery 1.

2.

Turn battery disconnect (1), if equipped, to the off position (2).

931001638

1

931002054

2

Connect the positive battery connection (1).

84522361 15/06/2011

A.30.A / 318

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

3.

Connect the negative battery connection (1).

931001641

3

931001828

4

NOTE: NEW HOLLAND CONSTRUCTION Battery disconnect is optional. 4.

Turn the battery disconnect (1), if equipped, to the on position (2).

84522361 15/06/2011

A.30.A / 319

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Repair NOTE: For Wiring Harness replacement, see Wiring harness - Replace (A.30.A) 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.

3.

4.

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

1

1z0o2004112112

2

1z0o2004112113

3

Peel back the cable from both ends of the damaged area and carefully cut away the inner cable cover at the damaged area and strip about 13 mm ( 1/2 in) of insulation from the wires. Do not cut away any wire strands. Using a suitable solvent, clean about 2 in ( 50 mm) from each cover end. Clean the grey cable cover and the individual leads. Twist two bare leads together for each damaged lead, being careful to match wire colours, then solder the leads using resin cored solder. Tape each repaired lead with vinyl insulation tape.

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.

84522361 15/06/2011

A.30.A / 320

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

5.

Allow the compound to cure then cover the area with insulating tape taking the tape well over each end of the repair. An overlap of at least 2 in ( 50 mm) of tape at each end is necessary. Check to ensure the repair is satisfactory and secure the repaired cable so that repeat damage is avoided.

NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent ingress of water or chemicals.

1z0o2004112114

84522361 15/06/2011

A.30.A / 321

4

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Wiring harness - Replace NOTE: For Wiring Harness repair, see Wiring harness - Repair (A.30.A) 1.

If a wire within the harness is found to be beyond repair or is open circuit, a jumper wire may be installed as a temporary repair until such time when a new harness assembly can be installed. Use the following procedure to install an additional wire: Locate the faulty wire using the procedures described in the fault code charts. Disconnect the affected connectors. If fitted carefully roll back the seal between the connector and harness outer covering. Remove the pins from the connector blocks of the affected wire using the appropriate removal tool found in the harness repair kit.

NOTE: Use the instructions supplied with the kit to ensure correct pin removal.

2.

1z0o2004112115

1

1z0o2004112116

2

From the harness repair kit select the correct pin for the connectors. Obtain locally the correct cross-sectional size wire and measure out the length required by following the harness routing. Join the new wire to the new pins as described in the harness repair kit and install one of the pins into its connector. If possible attempt to run the new wire within the existing harness outer covering, if this is not possible run the wire along the harness, securing regularly with suitable ties. With the wire correctly routed instal the second terminal into its connector block. Replace the connector seal if removed. To ensure that the repair has been effective check for continuity of the new wire using a suitable multimeter.

NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent ingress of water or chemicals.

84522361 15/06/2011

A.30.A / 322

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Testing Diode Testing Test Point N° 1 Condition Disconnect the connector from the diode. Using a multi-meter on the diode setting, Check measure the diode from pin to pin in both directions.

Expected Result Result The reading should be near the range of 0.3 V to 0.7 V one way, and infinite the other.

84522361 15/06/2011

A.30.A / 323

Other Result (Possible Cause) Result If reading is the same in both directions, the diode is shorted. If reading is near 3 V or infinite in both directions, the diode is open. Action Replace diode.

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

ELECTRICAL POWER SYSTEM - Testing General Wire Testing Test Point N° 1 Condition Circuit not functioning. Check Check wire run for an open circuit by following ELECTRICAL POWER SYSTEM - Electrical test Open Circuit (A.30.A). 2 Condition Circuit not functioning. Unless checking the ground network, Check Check wire run for a short circuit to ground by following ELECTRICAL POWER SYSTEM - Electrical test Short to Ground (A.30.A). 3 Condition Circuit not functioning. Check Check wire run for a short circuit to voltage by following ELECTRICAL POWER SYSTEM - Electrical test Short to Voltage (A.30.A).

Expected Result Result Wire not broken. Action Go to test 2

Other Result (Possible Cause) Result Wire is broken. Action Follow Wiring harness - Repair (A.30.A)

Result Wire not shorted. Action Go to test 3

Result Wire is shorted. Action Follow Wiring harness - Repair (A.30.A)

Result Wire not shorted. Action The fault may be intermittent. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. If no damage is found, continue operation.

Result Wire is shorted. Action Follow Wiring harness - Repair (A.30.A)

84522361 15/06/2011

A.30.A / 324

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - Testing Accessory Relay Control NOTE: Use schematics Wiring harness - Electrical schematic frame 03 (A.30.A) Wiring harness - Electrical schematic frame 04 (A.30.A) Test Point N° 1 Condition Remove the ACCESSORY RELAY K-018 from the MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008. Check Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C12 and ground. 2 Condition With the relay removed, and the ignition on, Check for voltage from MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C12 and ground. 3 Condition Disconnect connector X-15 from the ACCESSORY BACKFEED DIODE V-004. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin D10 and connector X-15. 4 Condition Disconnect connector X-15 from the ACCESSORY BACKFEED DIODE V-004 Check the diode using ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A). 5 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-C23 pin 22 and connector X-15.

Expected Result Result No wire problems. Action Go to test 2

Other Result (Possible Cause) Result Wire problems are found. Action Repair or replace broken wire 948/ 985/983 (Black).

Result 12 V Action The relay control circuit wiring is good. Go to Fuse and relay box Testing Relay Testing (A.50.A) to test relay. Result No wire problems Action Go to test 4

Result 0V Action Go to test 3

Result Wire problems are found. Action Repair or replace broken wire 139 (Orange) / 175 (White) (EH) / 153 (Black).

Result Test satisfactory. Action Go to test 5

Result Diode is faulty. Action Replace the diode.

Result No wire problems. Action Use Data bus - General specification Instrument Cluster pin information (A.50.A) to check INSTRUMENT CLUSTER pin 22.

Result Wire problems are found. Action Repair or replace broken wire 137 (White).

84522361 15/06/2011

A.30.A / 325

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - Testing Condenser Relay Control NOTE: Use schematics Wiring harness - Electrical schematic frame 17 (A.30.A) Test Point N° 1 Condition Disconnect connector X-111 from the CONDENSER RELAY K-020. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-111 pin 85 and ground. 2 Condition With the relay removed, and the ignition and HVAC controls on, Check for voltage between connector X-111 pin 86 and ground.

Expected Result Result No wire problems. Action Go to test 2

Result 12 V Action The relay control circuit wiring is good. Go to Fuse and relay box Testing Relay Testing (A.50.A) to test relay. Result 3 Condition Use ELECTRICAL POWER SYS- No wire problems. TEM - Testing General Wire Test- Action ing (A.30.A) to Electronic A/C control • Check Testing A/C Switch wire condition between connector (E.40.C) for further testX-111 pin 86 and connector X-HVC1 ing. pin 6.

84522361 15/06/2011

A.30.A / 326

Other Result (Possible Cause) Result Wire problems are found. Action Repair or replace broken wire 1087/ 1088/1093 (Black).

Result 0V Action Go to test 3

Result Wire problems are found. Action Repair or replace broken wire 840/ 837 (White).

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - Testing Crank Relay Control NOTE: Use schematics Wiring harness - Electrical schematic frame 03 (A.30.A) Wiring harness - Electrical schematic frame 04 (A.30.A) Test Point N° 1 Condition Remove the CRANK RELAY K-007 from the MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin A6 and ground. 2 Condition With the relay removed, and the ignition in the crank position, Check for voltage from MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin B4 and ground. 3 Condition Disconnect connector X-C23 from the Instrument Cluster. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin B4 and connector X-C23 pins 9 and 11. 4 Condition (For EH machines) disconnect connector X-CN2B from the UCM, use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin B4 and connector X-CN2B pin 24.

Expected Result Result No wire problems. Action Go to test 2

Other Result (Possible Cause) Result Wire problems are found. Action Repair or replace broken wire 944/ 985/983 (Black).

Result 12 V Action The relay control circuit wiring is good. Go to Fuse and relay box Testing Relay Testing (A.50.A) to test relay. Result No wire problems. Action (For Mech machines) use Data bus - General specification Instrument Cluster pin information (A.50.A) to check INSTRUMENT CLUSTER pins 9 and 11. Go to test 4

Result 0V Action Go to test 3

Result No wire problems. Action Use Data bus - General specification Instrument Cluster pin information (A.50.A) to check INSTRUMENT CLUSTER pins 9 and 11.

84522361 15/06/2011

A.30.A / 327

Result Wire problems are found. Action Repair or replace broken wire 630 (EH)/628/622 (White) or 630 (EH)/ 628/623 (White).

Result Wire problems are found. Action Repair or replace broken wire 630 (White) / 532 (Yellow).

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - Testing Engine Preheat Relay Control NOTE: Use schematics Wiring harness - Electrical schematic frame 03 (A.30.A) Wiring harness - Electrical schematic frame 11 (A.30.A) Test Point N° 1 Condition Disconnect connector X-PRHT from the ENGINE PREHEAT RELAY K-004. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-PRHT pin 2 and ground. 2 Condition With the relay removed, use Cold start aid - Overview Engine preheat (B.80.A) to set up conditions for the preheat system to turn on. Check for voltage from connector X-PRHT pin 1 and ground. 3 Condition Disconnect connector X-C23 from the Instrument Cluster. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-PRHT pin 1 and connector X-C23 pin 8 (EH) 7 (Mech).

Expected Result Result No wire problems. Action Go to test 2

Other Result (Possible Cause) Result Wire problems are found. Action Repair or replace broken wire 963/ 968/983 (Black).

Result 12 V Action The relay control circuit wiring is good. Go to Fuse and relay box Testing Relay Testing (A.50.A) to test relay.

Result 0V Action Go to test 3

Result No wire problems. Action Use Data bus - General specification Instrument Cluster pin information (A.50.A) to check INSTRUMENT CLUSTER pin 8 (EH) 7 (Mech).

Result Wire problems are found. Action Repair or replace broken wire 641 (White).

84522361 15/06/2011

A.30.A / 328

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - Testing Front Electric Relay Control NOTE: Use schematics Wiring harness - Electrical schematic frame 03 (A.30.A) Wiring harness - Electrical schematic frame 05 (A.30.A) Test Point N° 1 Condition Remove the Front Electric Relay K-017 from the ACCESSORY POWER DISTRIBUTION. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between ACCESSORY POWER DISTRIBUTION pin C12 and ground. 2 Condition With the relay removed, and the ignition on, Check for voltage from ACCESSORY POWER DISTRIBUTION pin D10 and ground.

Expected Result Result No wire problems. Action Go to test 2

Result 12 V Action The relay control circuit wiring is good. Go to Fuse and relay box Testing Relay Testing (A.50.A) to test relay. Result 3 Condition Disconnect connector X-15 from the Test satisfactory. ACCESSORY BACKFEED DIODE V-004 Action Go to test 4 Check the diode using ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A). Result 4 Condition Use ELECTRICAL POWER SYS- No wire problems. TEM - Testing General Wire Test- Action Go to test 5 ing (A.30.A) to Check wire condition between ACCESSORY POWER DISTRIBUTION pin D10 and connector X-15. 5 Condition Result Disconnect connector X-C23 from No wire problems. the Instrument Cluster. Use ELEC- Action TRICAL POWER SYSTEM - Test- Use Data bus - General speciing General Wire Testing (A.30.A) fication Instrument Cluster pin information (A.50.A) to check to INSTRUMENT CLUSTER pin 22. Check wire condition between connector X-C23 pin 22 and connector X-15.

84522361 15/06/2011

A.30.A / 329

Other Result (Possible Cause) Result Wire problems are found. Action Repair or replace broken wire 974/ 1008/1014 (Black).

Result 0V Action Go to test 3

Result Diode is faulty. Action Replace the diode.

Result Wire problems are found. Action Repair or replace broken wire 146/ 141 /175 (EH) (White) / 153 (Black).

Result Wire problems are found. Action Repair or replace broken wire 137 (White).

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - Testing Lights Relay #1 Control NOTE: Use schematics Wiring harness - Electrical schematic frame 04 (A.30.A) Test Point N° 1 Condition Remove the LIGHTS RELAY #1 K-001 from the MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin A12 and ground. 2 Condition With the relay removed, use LIGHTING SYSTEM - Overview Lighting (A.40.A) to set up conditions for the Front Work Lamps to turn on. Check for voltage from MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin B10 and ground. 3 Condition Disconnect connector X-311 from the LAMP SELECTOR SWITCH S-012. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin B10 and connector X-311 pin 3.

Expected Result Result No wire problems. Action Go to test 2

Other Result (Possible Cause) Result Wire problems are found. Action Repair or replace broken wire 946/ 985/983 (Black).

Result 12 V Action The relay control circuit wiring is good. Go to Fuse and relay box Testing Relay Testing (A.50.A) to test relay.

Result 0V Action Go to test 3

Result No wire problems. Action See LIGHTING SYSTEM - Testing Lamp Selector Switch (A.40.A) for further testing.

Result Wire problems are found. Action Repair or replace broken wire 325 (White) / 790 (Violet).

84522361 15/06/2011

A.30.A / 330

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - Testing Lights Relay #2 Control NOTE: Use schematics Wiring harness - Electrical schematic frame 04 (A.30.A) Test Point N° 1 Condition Remove the LIGHTS RELAY #2 K-002 from the MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin A9 and ground. 2 Condition With the relay removed, use LIGHTING SYSTEM - Overview Lighting (A.40.A) to set up conditions for the Rear Work Lamps to turn on. Check for voltage from MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin B7 and ground. 3 Condition Disconnect connector X-311 from the LAMP SELECTOR SWITCH S-012. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin B7 and connector X-311 pin 5. 4 Condition Remove SIDE LAMPS FUSE from the MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008. Check for continuity across SIDE LAMPS FUSE.

Expected Result Result No wire problems. Action Go to test 2

Other Result (Possible Cause) Result Wire problems are found. Action Repair or replace broken wire 945/ 985/983 (Black).

Result 12 V Action The relay control circuit wiring is good. Go to Fuse and relay box Testing Relay Testing (A.50.A) to test relay.

Result 0V Action Go to test 3

Result No wire problems. Action See LIGHTING SYSTEM - Testing Lamp Selector Switch (A.40.A) for further testing.

Result Wire problems are found. Action Go to test 4

Result Result Fuse is blown. 0Ω Action Action Repair or replace broken wire 709 Replace the fuse with same type and amp rating. (White) / 708/792 (Violet).

84522361 15/06/2011

A.30.A / 331

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - Testing Main Power Relay Control NOTE: Wiring Wiring Wiring

Use schematics harness - Electrical schematic frame 03 (A.30.A) harness - Electrical schematic frame 04 (A.30.A) harness - Electrical schematic frame 14 (A.30.A)

Test Point N° 1 Condition Remove the MAIN POWER RELAY K-009 from the MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C9 and ground. 2 Condition With the relay removed, and the ignition on, Check for voltage from MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin D7 and ground. 3 Condition Disconnect connector X-316 from the IGNITION BACKFEED DIODE V-007. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin D7 and connector X-316 pin B.

Expected Result Result No wire problems. Action Go to test 2

Other Result (Possible Cause) Result Wire problems are found. Action Repair or replace broken wire 947/ 985/983 (Black).

Result 12 V Action The relay control circuit wiring is good. Go to Fuse and relay box Testing Relay Testing (A.50.A) to test relay. Result No wire problems. Action See Start control - Testing Ignition Switch (B.80.A) for further testing.

Result 0V Action Go to test 3

84522361 15/06/2011

A.30.A / 332

Result Wire problems are found. Action Repair or replace broken wire 144 (Orange).

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - Testing Option Relay Control NOTE: Use schematics Wiring harness - Electrical schematic frame 03 (A.30.A) Wiring harness - Electrical schematic frame 05 (A.30.A) Test Point N° 1 Condition Remove the OPTION RELAY K-019 from the ACCESSORY POWER DISTRIBUTION. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between ACCESSORY POWER DISTRIBUTION pin A12 and ground. 2 Condition With the relay removed, and the ignition on, Check for voltage from ACCESSORY POWER DISTRIBUTION pin B10 and ground.

Expected Result Result No wire problems. Action Go to test 2

Result 12 V Action The relay control circuit wiring is good. Go to Fuse and relay box Testing Relay Testing (A.50.A) to test relay. Result 3 Condition Disconnect connector X-15 from the Test satisfactory. ACCESSORY BACKFEED DIODE V-004 Action Go to test 4 Check the diode using ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A). Result 4 Condition Use ELECTRICAL POWER SYS- No wire problems. TEM - Testing General Wire Test- Action Go to test 5 ing (A.30.A) to Check wire condition between ACCESSORY POWER DISTRIBUTION pin B10 and connector X-15. 5 Condition Result Disconnect connector X-C23 from No wire problems. the Instrument Cluster. Use ELEC- Action TRICAL POWER SYSTEM - Test- Use Data bus - General speciing General Wire Testing (A.30.A) fication Instrument Cluster pin information (A.50.A) to check to INSTRUMENT CLUSTER pin 22. Check wire condition between connector X-C23 pin 22 and connector X-15.

84522361 15/06/2011

A.30.A / 333

Other Result (Possible Cause) Result Wire problems are found. Action Repair or replace broken wire 972/ 1008/1014 (Black).

Result 0V Action Go to test 3

Result Diode is faulty. Action Replace the diode.

Result Wire problems are found. Action Repair or replace broken wire 148/ 141 /175 (EH) (White) / 153 (Black).

Result Wire problems are found. Action Repair or replace broken wire 137 (White).

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Fuse and relay box - Testing UCM Power Relay Control L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

NOTE: Use schematics Wiring harness - Electrical schematic frame 03 (A.30.A) Wiring harness - Electrical schematic frame 05 (A.30.A) Test Point N° 1 Condition Remove the UCM Power Relay K-003 from the ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 Z-FUSE2. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 Z-FUSE2 pin A9 and ground. 2 Condition With the relay removed, and the ignition on, Check for voltage from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 Z-FUSE2 pin B7 and ground. 3 Condition Disconnect connector X-15 from the ACCESSORY BACKFEED DIODE V-004 Check the diode using ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A). 4 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 Z-FUSE2 pin B7 and connector X-15 pin 1. 5 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-C23 pin 22 and connector X-15 pin 1.

Expected Result Result No wire problems. Action Go to test 2

Other Result (Possible Cause) Result Wire problems are found. Action Repair or replace broken wire 1067/ 1069/983 (Black).

Result 12 V Action The relay control circuit wiring is good. Go to Fuse and relay box Testing Relay Testing (A.50.A) to test relay. Result Test satisfactory. Action Go to test 4

Result 0V Action Go to test 3

Result Diode is faulty. Action Replace the diode.

Result No wire problems. Action Go to test 5

Action If wire problems are found. Repair or replace broken wire 335/ 175 (White) / 153 (Black).

Result No wire problems. Action Use Data bus - General specification Instrument Cluster pin information (A.50.A) to check INSTRUMENT CLUSTER pin 22.

Result If wire problems are found. Action Repair or replace broken wire 137 (White).

84522361 15/06/2011

A.30.A / 334

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

Auxiliary power connection - Testing Electric Auxiliary Hydraulic On/Off Switch NOTE: Use schematics Wiring harness - Electrical schematic frame 05 (A.30.A) Wiring harness - Electrical schematic frame 06 (A.30.A) Wiring harness - Electrical schematic frame 29 (A.30.A) (EH) Wiring harness - Electrical schematic frame 24 (A.30.A) (Mech) Test Point N° 1 Condition Remove FE ON/OFF FUSE from the ACCESSORY POWER DISTRIBUTION Check for continuity across FE ON/OFF FUSE. 2 Condition With the ignition on, Check for voltage from ACCESSORY POWER DISTRIBUTION pin E1 and ground. 3 Condition Disconnect connector X-304 from the ELECTRIC AUXILIARY HYDRAULIC ON/OFF SWITCH Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between ACCESSORY POWER DISTRIBUTION pin E2 and connector X-304 pin E. 4 Check Using a multi-meter, check for resistance between ELECTRIC AUXILIARY HYDRAULIC ON / OFF SWITCH pins D and E while cycling the ELECTRIC AUXILIARY HYDRAULIC ON / OFF SWITCH. 5 Condition Disconnect Multifunction Attachment connector X-107. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-107 pin J and connector X-304 pin D.

Expected Result Result 0Ω Action Go to test 2

Other Result (Possible Cause) Result Fuse is blown. Action Replace the fuse with same type and amp rating.

Result 12 V Action Go to test 3

Result 0V Action There is a problem in the DC distribution system upstream of FE ON/OFF FUSE Result Wire problems are found. Action Repair or replace broken wire 129 (Orange).

Result No wire problems. Action Go to test 4

Result For each resistance check, 0 Ω in one position, infinite resistance in the other. Action Go to test 5

Result 0 Ω in both positions or infinite resistance in both positions. Action The ELECTRIC AUXILIARY HYDRAULIC ON / OFF SWITCH has failed. Replace the switch.

Result No wire problems. Action The fault may be intermittent. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. If no damage is found, continue operation.

Result Wire problems are found. Action Locate and repair or replace broken wire 856/422 (White) or adjacent wiring.

84522361 15/06/2011

A.30.A / 335

Index HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A ELECTRICAL POWER SYSTEM - 30.A Wiring harness - Electrical schematic frame 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Wiring harness - Electrical schematic frame 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Wiring harness - Electrical schematic frame 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Wiring harness - Electrical schematic frame 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Wiring harness - Electrical schematic frame 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Wiring harness - Electrical schematic frame 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Wiring harness - Electrical schematic frame 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Wiring harness - Electrical schematic frame 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 Wiring harness - Electrical schematic frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 Wiring harness - Electrical schematic frame 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Wiring harness - Electrical schematic frame 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 L223, L225, L230, C227, C232, C238

Wiring harness - Electrical schematic frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 L213, L215, L218, L220

Wiring harness - Electrical schematic frame 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Wiring harness - Electrical schematic frame 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 Wiring harness - Electrical schematic frame 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 L213 WE, L215 WE, L218 WE, L220 WE, L223 WE, L225 WE, L230 WE, C227 WE, C232 WE, C238 WE

Wiring harness - Electrical schematic frame 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Wiring harness - Electrical schematic frame 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Wiring harness - Electrical schematic frame 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Wiring harness - Electrical schematic frame 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 Wiring harness - Electrical schematic frame 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Wiring harness - Electrical schematic frame 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 L223, L225, L230, C227, C232, C238

Wiring harness - Electrical schematic frame 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 Wiring harness - Electrical schematic frame 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 Wiring harness - Electrical schematic frame 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Wiring harness - Electrical schematic frame 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Wiring harness - Electrical schematic frame 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Wiring harness - Electrical schematic frame 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Wiring harness - Electrical schematic frame 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Wiring harness - Electrical schematic frame 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls 84522361 15/06/2011

A.30.A / 336

Wiring harness - Electrical schematic frame 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Wiring harness - Electrical schematic frame 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Wiring harness - Electrical schematic frame 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Wiring harness - Electrical schematic frame 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 L223, L225, L230, C227, C232, C238

Wiring harness - Detailed view Harness Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 Auxiliary power connection - Testing Electric Auxiliary Hydraulic On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 Battery - Check Maintenance Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Battery - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Battery - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Connector - Component diagram 01 - Connector X-10 to Connector X-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Connector - Component diagram 02 - Connector X-14 to Connector X-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Connector - Component diagram 03 - Connector X-161 to Connector X-194 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Connector - Component diagram 04 - Connector X-195 to Connector X-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Connector - Component diagram 05 - Connector X-22 to Connector X-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Connector - Component diagram 06 - Connector X-233 to Connector X-275 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Connector - Component diagram 07 - Connector X-28 to Connector X-303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Connector - Component diagram 08 - Connector X-304 to Connector X-317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Connector - Component diagram 09 - Connector X-318 to Connector X-332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Connector - Component diagram 10 - Connector X-333 to Connector X-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Connector - Component diagram 11 - Connector X-365 to Connector X-406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Connector - Component diagram 12 - Connector X-407 to Connector X-430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Connector - Component diagram 13 - Connector X-432 to Connector X-502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Connector - Component diagram 14 - Connector X-502A to Connector X-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Connector - Component diagram 15 - Connector X-512 to Connector X-52A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Connector - Component diagram 16 - Connector X-52B to Connector X-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Connector - Component diagram 17 - Connector X-75 to Connector X-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Connector - Component diagram 18 - Connector X-93 to Connector X-AC_COMP . . . . . . . . . . . . . . . . . . . . . . . . 114 Connector - Component diagram 19 - Connector X-ACC to Connector X-C01A . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Connector - Component diagram 20 - Connector X-C01B to Connector X-CAB_GNDB . . . . . . . . . . . . . . . . . . . . 121 Connector - Component diagram 21 - Connector X-CC1A to Connector X-CHS_GND_RR . . . . . . . . . . . . . . . . . 126 Connector - Component diagram 22 - Connector X-CN1A to Connector X-CN4A . . . . . . . . . . . . . . . . . . . . . . . . . 132 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Connector - Component diagram 23 - Connector X-CN4B to Connector X-ECC2A . . . . . . . . . . . . . . . . . . . . . . . . 139 Connector - Component diagram 24 - Connector X-ECC2B to Connector X-ECC6B . . . . . . . . . . . . . . . . . . . . . . . 144 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Connector - Component diagram 25 - Connector X-EGR to Connector X-FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . 150 84522361 15/06/2011

A.30.A / 337

Connector - Component diagram 26 - Connector X-FUSE1 to Connector X-HORN-GND . . . . . . . . . . . . . . . . . . 153 Connector - Component diagram 27 - Connector X-HORN-PWR to Connector X-K-C4 . . . . . . . . . . . . . . . . . . . . 157 Connector - Component diagram 28 - Connector X-NEG_TERM_A to Connector X-POS_TERM_A . . . . . . . . . 159 Connector - Component diagram 29 - Connector X-POS_TERM_B to Connector X-UJMR . . . . . . . . . . . . . . . . . 164 Connector - Component diagram 99 Engine connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 L223, L225, L230, C227, C232, C238

Connector - Component identification Engine connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 L223, L225, L230, C227, C232, C238

ELECTRICAL POWER SYSTEM - Component identification Diode Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ELECTRICAL POWER SYSTEM - Component identification Fuse Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

ELECTRICAL POWER SYSTEM - Component identification Fuse Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

ELECTRICAL POWER SYSTEM - Component identification Lighting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 ELECTRICAL POWER SYSTEM - Component identification Miscellaneous Index . . . . . . . . . . . . . . . . . . . . . . . . . 25 ELECTRICAL POWER SYSTEM - Component identification Motor Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ELECTRICAL POWER SYSTEM - Component identification Relay Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ELECTRICAL POWER SYSTEM - Component identification Sensor Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ELECTRICAL POWER SYSTEM - Component identification Solenoid Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ELECTRICAL POWER SYSTEM - Component identification Switch Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 ELECTRICAL POWER SYSTEM - Electrical test Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 ELECTRICAL POWER SYSTEM - Electrical test Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 ELECTRICAL POWER SYSTEM - Electrical test Short to Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 ELECTRICAL POWER SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 ELECTRICAL POWER SYSTEM - Overview Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ELECTRICAL POWER SYSTEM - Overview Pulse width modulation (PWM) solenoid valves . . . . . . . . . . . . . . . 40 ELECTRICAL POWER SYSTEM - Overview Resistance devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ELECTRICAL POWER SYSTEM - Overview Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ELECTRICAL POWER SYSTEM - Overview Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ELECTRICAL POWER SYSTEM - Testing Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 ELECTRICAL POWER SYSTEM - Testing General Wire Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Fuse and relay box - General specification Accessory Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuse and relay box - General specification Main Power Distribution Fuse Block 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuse and relay box - Overview Location and access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Fuse and relay box - Testing Accessory Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 Fuse and relay box - Testing Condenser Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 Fuse and relay box - Testing Crank Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Fuse and relay box - Testing Engine Preheat Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 Fuse and relay box - Testing Front Electric Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 Fuse and relay box - Testing Lights Relay #1 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Fuse and relay box - Testing Lights Relay #2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 Fuse and relay box - Testing Main Power Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 Fuse and relay box - Testing Option Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

84522361 15/06/2011

A.30.A / 338

Fuse and relay box - Testing UCM Power Relay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Fuse and relay box Fuse - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Fuse and relay box Relay - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Sensing system - General specification Resistance to Temperature Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . 8 Sensing system - Overview Speed and position sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 Sensing system - Overview Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Wiring harness - Electrical schematic frame 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Wiring harness - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Wiring harness - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

84522361 15/06/2011

A.30.A / 339

84522361 15/06/2011

A.30.A / 340

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A LIGHTING SYSTEM - 40.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

A.40.A / 1

Contents HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A LIGHTING SYSTEM - 40.A

DIAGNOSTIC LIGHTING SYSTEM Testing Lamp Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Turn/hazard light Testing Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 L213 WE, L215 WE, L218 WE, L220 WE, L223 WE, L225 WE, L230 WE, C227 WE, C232 WE, C238 WE

Testing Hazard Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L213 WE, L215 WE, L218 WE, L220 WE, L223 WE, L225 WE, L230 WE, C227 WE, C232 WE, C238 WE

Testing Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L213 WE, L215 WE, L218 WE, L220 WE, L223 WE, L225 WE, L230 WE, C227 WE, C232 WE, C238 WE

84522361 15/06/2011

A.40.A / 2

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - LIGHTING SYSTEM

LIGHTING SYSTEM - Testing Lamp Selector Switch NOTE: Use schematics Wiring harness - Electrical schematic frame 04 (A.30.A) Wiring harness - Electrical schematic frame 08 (A.30.A) Test Point N° 1 Condition Disconnect connector X-311 from the LAMP SELECTOR SWITCH S-012. Check Using a multi-meter, check for resistance between LAMP SELECTOR SWITCH pins 2 and 3 pins 2 and 4 pins 2 and 5 while cycling the LAMP SELECTOR SWITCH. 2 Condition Disconnect connector X-311 from the LAMP SELECTOR SWITCH S-012. With the ignition on, Check for voltage from connector X-311 pin 2 and ground. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C10 and connector X-311 pin 2. 4 Condition Use Fuse and relay box - Testing Accessory Relay Control (A.30.A) to check ACCESSORY RELAY K-018. 5 Condition Use Fuse and relay box - Testing Lights Relay #1 Control (A.30.A) to check LIGHTING RELAY #1 K-001. 6 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-311 pin 4 and MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin E7. 7 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-311 pin 5 and MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin E3.

Expected Result Result For each resistance check, 0 Ω in one position, infinite resistance in all others. Action Go to test 2

Other Result (Possible Cause) Result 0 Ω in multiple positions or infinite resistance in all positions. Action The LAMP SELECTOR SWITCH has failed. Replace the switch.

Result 12 V Action Go to test 5

Result 0V Action Go to test 3

Result No wire problems Action Go to test 4

Action If wire problems are found, repair or replace broken wire 125/ 123 (Orange).

Result Test is satisfactory Action There is a problem in the DC distribution system upstream of ACCESSORY RELAY. Result Test is satisfactory Action Go to test 6 Result No wire problems Action Go to test 7

Action If problems were found and corrected, this test is complete.

Result No wire problems Action there is a problem in the lighting circuitry, see LIGHTING SYSTEM - Overview Lighting (A.40.A) for more information.

84522361 15/06/2011

A.40.A / 3

Action If problems were found and corrected, this test is complete. Action If wire problems are found, repair or replace broken wire 791/ 701 (Violet).

Action If wire problems are found, repair or replace broken wire 792 (Violet).

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - LIGHTING SYSTEM

Turn/hazard light - Testing Flasher Module L213 WE, L215 WE, L218 WE, L220 WE, L223 WE, L225 WE, L230 WE, C227 WE, C232 WE, C238 WE

NOTE: Use schematics Wiring harness - Electrical schematic frame 05 (A.30.A) Wiring harness - Electrical schematic frame 16 (A.30.A) Test Point N° 1 Condition Remove FLASHER / BRAKE FUSE from the ACCESSORY POWER DISTRIBUTION Check for continuity across FLASHER / BRAKE FUSE 2 Condition With the fuse removed, and the key on, Check for voltage from ACCESSORY POWER DISTRIBUTION pin E9 and ground 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin E10 and connector X-411 pin 30. 4 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-411 pin 85 and ground.

Expected Result Result 0Ω Action Go to test 2

Other Result (Possible Cause) Result Fuse is blown. Action Replace the fuse with same type and amp rating.

Result 12 V Action Go to test 3

Result 0V Action There is a problem in the DC distribution system upstream of FLASHER / BRAKE FUSE. Result Wire problems are found. Action Locate and repair or replace broken wire 156 (Red) or adjacent wiring.

Result No wire problems Action Go to test 4

Result Wire problems are found. Action Locate and repair or replace broken See the following for further testing wire 981/986/1014 (Black) or adjaTurn/hazard light - Test- cent wiring. • ing Turn Signal Switch (A.40.A) Result No wire problems Action

•

Turn/hazard light - Testing Hazard Lamp Switch (A.40.A)

84522361 15/06/2011

A.40.A / 4

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - LIGHTING SYSTEM

Turn/hazard light - Testing Hazard Lamp Switch L213 WE, L215 WE, L218 WE, L220 WE, L223 WE, L225 WE, L230 WE, C227 WE, C232 WE, C238 WE

NOTE: Use schematics Wiring harness - Electrical schematic frame 06 (A.30.A) Wiring harness - Electrical schematic frame 16 (A.30.A) Test Point N° 1 Condition Disconnect connector X-302 from the HAZARD LAMP SWITCH S-041. Check Using a multi-meter, check for resistance between HAZARD LAMP SWITCH pins B and A pins E and F while cycling the HAZARD LAMP SWITCH. 2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-302 pins B and E and connector X-411 pin 87A. 3 Condition Disconnect connector X-HZRDDIODE from the HAZARD SWITCH INDICATOR BACKFEED DIODE V-010. Check the diode using ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A).

Expected Result Result For each resistance check, 0 Ω in one position, infinite resistance in the other. Action Go to test 2

Other Result (Possible Cause) Result 0 Ω in both positions or infinite resistance in both positions. Action The HAZARD LAMP SWITCH has failed. Replace the switch.

Result No wire problems. Action Go to test 3

Result Wire problems are found. Action Repair or replace broken wire 784(White), 785 (Orange), or 769 (Orange).

Result Test satisfactory. Action

Result Diode is faulty. Action Replace the diode.

See the following for further testing •

Turn/hazard light - Testing Flasher Module (A.40.A)

•

Turn/hazard light - Testing Turn Signal Switch (A.40.A)

•

LIGHTING - Overview (A.40.A)

84522361 15/06/2011

A.40.A / 5

SYSTEM Lighting

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - LIGHTING SYSTEM

Turn/hazard light - Testing Turn Signal Switch L213 WE, L215 WE, L218 WE, L220 WE, L223 WE, L225 WE, L230 WE, C227 WE, C232 WE, C238 WE

NOTE: Use schematics Wiring harness - Electrical schematic frame 07 (A.30.A) Wiring harness - Electrical schematic frame 16 (A.30.A) Test Point N° 1 Condition Disconnect connector X-408 (EH) X-407 (Mech) from the LEFT HAND CONTROL HANDLE Z-005. Check Using a multi-meter, check for resistance between TURN SIGNAL SWITCH S-027 pins 5 and 6 pins 5 and 7 while cycling the TURN SIGNAL SWITCH. 2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-408 (EH) X-407 (Mech) pin 5 and connector X-411 pin 87A. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-408 (EH) X-407 (Mech) pin 6 and connector X-302 pin A. 4 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-408 (EH) X-407 (Mech) pin 7 and connector X-HZRDDIODE pin B. 5 Condition Disconnect connector X-HZRDDIODE from the HAZARD SWITCH INDICATOR BACKFEED DIODE V-010. Check the diode using ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A).

Expected Result Result For each resistance check, 0 Ω in one position, infinite resistance in the other. Action Go to test 2

Other Result (Possible Cause) Result 0 Ω in both positions or infinite resistance in both positions. Action The TURN SIGNAL SWITCH has failed. Replace the switch.

Result No wire problems. Action Go to test 3

Result Wire problems are found. Action Locate and repair or replace broken wire 770/769 (Orange) or adjacent wiring.

Result No wire problems. Action Go to test 4

Result Wire problems are found. Action Locate and repair or replace broken wire 776/768 (Violet) or adjacent wiring.

Result No wire problems. Action Go to test 5

Result Wire problems are found. Action Locate and repair or replace broken wire 765 (Violet) or adjacent wiring.

Result Test satisfactory. Action

Result Diode is faulty. Action Replace the diode.

See the following for further testing •

Turn/hazard light - Testing Hazard Lamp Switch (A.40.A)

•

Turn/hazard light - Testing Flasher Module (A.40.A)

84522361 15/06/2011

A.40.A / 6

Index HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A LIGHTING SYSTEM - 40.A LIGHTING SYSTEM - Testing Lamp Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Turn/hazard light - Testing Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 L213 WE, L215 WE, L218 WE, L220 WE, L223 WE, L225 WE, L230 WE, C227 WE, C232 WE, C238 WE

Turn/hazard light - Testing Hazard Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L213 WE, L215 WE, L218 WE, L220 WE, L223 WE, L225 WE, L230 WE, C227 WE, C232 WE, C238 WE

Turn/hazard light - Testing Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L213 WE, L215 WE, L218 WE, L220 WE, L223 WE, L225 WE, L230 WE, C227 WE, C232 WE, C238 WE

84522361 15/06/2011

A.40.A / 7

84522361 15/06/2011

A.40.A / 8

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A ELECTRONIC SYSTEM - 50.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

A.50.A / 1

Contents HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A ELECTRONIC SYSTEM - 50.A

TECHNICAL DATA Data bus General specification Instrument Cluster pin information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Electronic service tool (EST) Overview EST overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Electronic service tool (EST) H1 - Calibration procedures Calibration Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

H1 - Calibration procedures Calibration Procedure Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

H1 - Calibration procedures Joystick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

H1 - Calibration procedures Ground Drive Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

H1 - Calibration procedures Throttle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

H1 - Calibration procedures Loader Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

H1 - Calibration procedures Loader Start Pressure Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control module

84522361 15/06/2011

A.50.A / 2

Vehical Control Module (VCM) - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Vehical Control Module (VCM) - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

DIAGNOSTIC Fuse and relay box Testing Relay Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

84522361 15/06/2011

A.50.A / 3

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

Data bus - General specification Instrument Cluster pin information The following tables include pin resistance information for the Instrument Cluster. After disconnecting connector X-C23 from the Instrument Cluster, use a multi-meter to check resistance from the desired pin to pin 20. The resulting value should be near the table value. Other values may indicate a failure of the Instrument Cluster. Mechanical Instrument Cluster A-002 pin information Pin

Signal

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Fuel Level Sender Hydraulic Oil Temperature Unswitched power CAN Hi Pilot Interlock CAN Lo Engine Preheat Park Brake Release Starter Relay Park Brake Switch Key Switch Start Seat Switch Lap Bar / Seat Belt Switch Hydraulic Loader Port Lock Hydraulic Filter Restriction Switch Air Filter Restriction Switch Door Switch Engine Oil Pressure Switch Engine RPM ECU Ground Main Power Relay Accessory Relay Ignition Power Ignition Power Engine Coolant Temperature Sender Fuel Solenoid

16 17 18 19 20 21 22 23 24 25 26

Resistance to ground (pin 20) (in Ω) 3.69 M 3.69 M 51.8 K 1.19 M 250 K 1.19 M 246 K 248 K 244 K 603 603 603 603 243 K 10.55 K

Input / Output Input Input Input I/O Output I/O Output Output Output Input Input Input Input Output Input

10.55 K 10.55 K 10.55 K 1.1 M N/A 244 K 248 K 9.95 K 9.95 K 3.7 M

Input Input Input Input N/A Output Output Input Input Input

244 K

Output

EH Instrument Cluster A-001 pin information Pin

Signal

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Fuel Level Sender Hydraulic Oil Temperature Unswitched power CAN Hi Open CAN Lo Fuel Solenoid Engine Preheat Starter Relay Open Key Switch Start Wake Up Open Hydraulic Enable Hydraulic Filter Restriction Switch

Resistance to ground (pin 20) (in Ω) 3.69 M 3.69 M 51.8 K 1.19 M

Input Input Input I/O

1.19 M 244 K 247 K 244 K

I/O Output Output Output

603 603

Input Input

243 K 10.55 K

Output Input

84522361 15/06/2011

A.50.A / 4

Input / Output

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

16 17 18 19 20 21 22 23 24 25 26

Air Filter Restriction Switch / EGR Door Switch Engine Oil Pressure Switch Open ECU Ground Main Power Relay Accessory Relay Ignition Power Ignition Power Engine Coolant Temperature Sender Open

10.55 K

Input

10.55 K 10.55 K

Input Input

N/A 244 K 248 K 9.95 K 9.95 K 3.7 M

N/A Output Output Input Input Input

84522361 15/06/2011

A.50.A / 5

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

Electronic service tool (EST) - Overview EST overview The instrument cluster has the ability to interface with the EST in a service setting to modify parameters, recall saved system faults, and update application software. It is recommended that the service technician attempt to retrieve trouble codes with the EST on every service call, due to the number of "White" codes, which are not displayed on the Instrument Cluster. The EST is interfaced to the cluster through the machine service plug. The EST and instrument cluster negotiate communication any time the EST is connected and operational, and the cluster is powered on. The EST connection allows service technicians to update cluster software in the field as updates become available. The EST is interfaced to the cluster through the machine service plug. The EST software provides the interface the technician uses to update the software.

84522361 15/06/2011

A.50.A / 6

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

Electronic service tool (EST) - H1 - Calibration procedures Calibration Requirements L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Calibration involves setting correct hardware parameters for joysticks, ground drive pumps, loader valve, and throttle mechanism. Unless noted otherwise, the operator has 30 seconds to complete each calibration step. The calibration procedure will have to be restarted if a step times out. The parameters associated with each calibration procedure will be saved when that particular procedure completes successfully. If there are problems completing one of the five calibration procedures, only that procedure will need to be repeated, not all five. The audible alarm and calibration messages will not be displayed if any error codes are active. If any calibration fails, see Electronic service tool (EST) - H1 - Calibration procedures Calibration Procedure Troubleshooting (A.50.A) for troubleshooting steps. 1.

2.

3.

The following software will be required •

CNH Electronic Service Tool (EST), version 6.3.0.0 or later.

•

If downloading new application software SL57 UCM Application Software (SSL_SL57_x-x-x-x.hx1), and SL57 Instrument Cluster software (SSLCluster_Vx_x_x_x.hx1)

If new software is available, download it before calibrating using the following steps. •

Connect the EST hardware to the machine diagnostic connector and laptop.

•

Flash the new SL57 Application Software onto the machine controller (UCM) with the Electronic Service Tool (EST) programming menu.

•

Flash the new instrument cluster (IC) software to the IC with the EST configuration menu.

•

Set the machine configurations (serial number, model, door, etc.) in the EST configuration menu.

Calibration Preparation Steps •

Connect the EST hardware to the machine diagnostic connector and laptop.

•

Open the EST configuration menu.

•

Clear any fault codes from the IC display by cycling the Aux Override button until the display is clear.

84522361 15/06/2011

A.50.A / 7

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

Electronic service tool (EST) - H1 - Calibration procedures Calibration Procedure Troubleshooting L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

These are the codes that may be encountered during calibration. If seen, check condition description and compare to calibration procedure prerequisite conditions. Display Text CD01

Condition Name Calibration Enable Fail

CD02

Calibration Sustain Fail

CD03

Device Fault

CD04

Calibration Timeout

CD05

Operator Interrupt

CD06

Calibration Value High

CD07

Calibration Value Low

CD08

Signal Unstable

1.

Condition Description Calibration Enable Condition(s) not met at time of initiation Calibration Sustain Condition(s) not met during cal routine Device Fault Calibration Sustain Condition(s) not met during cal routine Calibration Step was not completed within allotted time Calibration interrupted by Operator via cluster Cal button Calibration value higher than upper-end of acceptance range Calibration value lower than lower-end of acceptance range Signal being calibrated outside of settling noise tolerance

Troubleshooting Suggestions 1.

For CD01 - CD05, restart calibration procedure with the 'START CALIBRATION' button. If this does not work, Press 'Exit' on EST calibration procedure and re-enter the calibration state and the individual calibration procedure.

2.

For CD-06 - CD-08, try 'Retry' button on EST. If this does not work, Press 'Exit' on the calibration procedure and re-enter the calibration state and the individual calibration procedure.

3.

Occasionally closing and reopening the EST is required to restart a calibration.

84522361 15/06/2011

A.50.A / 8

Software Reaction Exit calibration and use old values Exit calibration and use old values Exit calibration and use old values

Exit calibration and use old values Exit calibration and use old values Beep and flash code - give operator a chance to retry cal step Beep and flash code - give operator a chance to retry cal step Beep and flash code - give operator a chance to retry cal step

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

Electronic service tool (EST) - H1 - Calibration procedures Joystick Calibration L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

The purpose of the Joystick Calibration is to calibrate the main axis of the left and right joystick and the proportional thumbwheel. 1.

Ensure the prerequisite requirements are complete per Electronic service tool (EST) - H1 - Calibration procedures Calibration Requirements (A.50.A).

2.

Ensure the following conditions are met •

Joysticks in Neutral

•

Proportional Auxiliary Roller Switch in Neutral

•

Key ON

•

Engine ON

•

Hydraulics OFF

•

Operator Present

•

No Joystick Related Fault Codes

3.

In the EST configuration menu, open the 'Calibration - Joystick' item.

4.

Press the 'SET UP CONTROLLER FOR CALIBRATION' button. •

5.

Press the 'START CALIBRATION' button. •

6.

Ensure that the text "C-J1" is displayed on the cluster screen.

Press and release the loader float button to start capturing step 1 values. •

7.

Ensure 'START CALIBRATION' is now active.

Verify that an audible beep is heard from the instrument cluster and the text "C-J2" is displayed on the cluster screen upon completion of step 1.

Move the proportional auxiliary roller switch to the upper or left detent (toward the smaller icon). Move both joysticks to the front right corner. Press and release the loader float button to start capturing step 2 values. •

Verify that an audible beep is heard from the instrument cluster and the text "C-J3" is displayed on the cluster screen upon completion of step 2.

84522361 15/06/2011

A.50.A / 9

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

8.

Move the proportional auxiliary roller switch to the lower or right detent (towards the larger icon). Move and hold both joysticks to the back left corner. Press and release the loader float button to start capturing step 3 values. •

Verify that an audible beep is heard from the instrument cluster upon completion of step 3.

•

Verify that the instrument cluster screen returns to normal message display.

84522361 15/06/2011

A.50.A / 10

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

Electronic service tool (EST) - H1 - Calibration procedures Ground Drive Calibration L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

The purpose of the Ground Drive Calibration is to calibrate the command current to a nominal pressure and calibrate the neutral position of the ground drive swashplate angles. This is a semi-automatic procedure, therefore most of the operator interaction is via the cluster display screen only. NOTE: It is not unusual to see a small amount of machine movement during calibrations the UCM finds the command current that brings the pump on stroke. Significant machine movement during calibration (more than 1 foot) is not expected and is a symptom of a problem in the system. 1.

Ensure the prerequisite requirements are complete per Electronic service tool (EST) - H1 - Calibration procedures Calibration Requirements (A.50.A).

2.

Ensure the following conditions are met •

No Joystick Related Fault Codes

•

No Ground Drive Related Fault Codes

•

Joysticks in Neutral

•

Proportional Auxiliary Roller Switch in Neutral

•

Key ON

•

Engine ON

•

Hydraulics ON

•

Hydraulic Oil Temperature between 15 °C (59.0 °F) and 80 °C (176.0 °F)

•

Operator Present

•

Engine RPM less than 1200 RPM

3.

In the EST configuration menu, open the 'Calibration - Ground Drive' item.

4.

Press the 'SET UP CONTROLLER FOR CALIBRATION' button. •

5.

Press the 'START CALIBRATION' button. •

6.

Ensure 'START CALIBRATION' is now active. Ensure that the text "C-G1" is displayed on the cluster screen.

Move the right joystick to the front right corner (away from the operator) and press and release the loader float button. Keep the right joystick in the top right corner for the entirety of the ground drive calibration. •

Verify that an audible beep is heard from the instrument cluster and the text "C-G2" is displayed on the cluster screen upon completion of step 1.

84522361 15/06/2011

A.50.A / 11

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

7.

Keep the right joystick at the top right corner (away from the operator). •

8.

Keep the right joystick at the top right corner (away from the operator). •

9.

Verify that an audible beep is heard from the instrument cluster upon completion of step 5.

Release the right joystick. •

12.

Verify that an audible beep is heard from the instrument cluster and the text "C-G5" is displayed on the cluster screen upon completion of step 4.

Keep the right joystick at the top right corner (away from the operator). •

11.

Verify that an audible beep is heard from the instrument cluster and the text "C-G4" is displayed on the cluster screen upon completion of step 3.

Keep the right joystick at the top right corner (away from the operator). •

10.

Verify that an audible beep is heard from the instrument cluster and the text "C-G3" is displayed on the cluster screen upon completion of step 2.

Verify that the EST Calibration Operation Status window says "Calibration Completed Successfully." Verify that the instrument cluster screen returns to normal message display.

Exit out of the Calibration - Ground Drive screen

84522361 15/06/2011

A.50.A / 12

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

Electronic service tool (EST) - H1 - Calibration procedures Throttle Calibration L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

The purpose of the Throttle Calibration is to calibrate the six key throttle position points to improve robustness of the load control algorithm. 1.

Ensure the prerequisite requirements are complete per Electronic service tool (EST) - H1 - Calibration procedures Calibration Requirements (A.50.A).

2.

Ensure the following conditions are met •

Joysticks in Neutral

•

Key ON

•

Engine ON

•

Hydraulics OFF

•

Operator Present

•

No Throttle Related Fault Codes

3.

In the EST configuration menu, open the 'Calibration - Hand Throttle' item.

4.

Press the 'SET UP CONTROLLER FOR CALIBRATION' button. •

5.

Press the 'START CALIBRATION' button. •

6.

Verify that an audible beep is heard from the instrument cluster and the text "C-T2" is displayed on the cluster screen upon completion of step 1.

Very slowly reduce the throttle to approximately 150 RPM below maximum engine RPM until audible alarm sounds and display changes to "C-T3". •

8.

Ensure that the text "C-T1" is displayed on the cluster screen.

Move the hand throttle lever to the maximum throttle end-stop position. Step on the foot throttle until it is fully depressed. Press and release the loader float button. •

7.

Ensure 'START CALIBRATION' is now active.

Verify that an audible beep is heard from the instrument cluster and the text "C-T3" is displayed on the cluster screen upon completion of step 2.

Pull the hand throttle lever to the minimum end-stop position. Ensure that the foot throttle is not depressed. Press and release the loader float button. •

Verify that an audible beep is heard from the instrument cluster and the text "C-T4" is displayed on the cluster screen upon completion of step 3.

84522361 15/06/2011

A.50.A / 13

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

9.

Very slowly increase the throttle to approximately 150 RPM above low idle until audible alarm sounds and display changes to "C-T5". •

10.

Adjust the hand throttle lever position such that the engine RPM display flashing on the instrument cluster screen is at 1750 +/- 150 RPM for ISM, 1600 +/150 RPM for F5C. Press and release the loader float button. •

11.

Verify that an audible beep is heard from the instrument cluster and the text "C-T5" is displayed on the cluster screen upon completion of step 4.

Verify that an audible beep is heard from the instrument cluster and the text "C-T6" is displayed on the cluster screen upon completion of step 5.

Adjust the hand throttle lever position such that the engine rpm display flashing on the instrument cluster screen is at 2400 +/- 150 RPM for ISM, 2100 +/150 RPM for F5C. Press and release the loader float button. •

Verify that an audible beep is heard from the instrument cluster upon completion of step 6. Verify that the EST Calibration Operation Status window says "Calibration Completed Successfully." Verify that the instrument cluster screen returns to normal message display.

84522361 15/06/2011

A.50.A / 14

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

Electronic service tool (EST) - H1 - Calibration procedures Loader Calibration L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

The purpose of the Loader Calibration Procedure is to calibrate the command current to a nominal pressure for each spool and calibrate the neutral position of the loader attachment spool sensors. This is a semi-automatic procedure, therefore most of the operator interaction is via the cluster display screen only. NOTE: It is not unusual to see a small amount of loader or bucket movement during calibration as the UCM finds the command current that shifts the valve spools. Significant implement movement during calibration (more than 1 foot) should not be expected and is a symptom of a problem in the system. 1.

Ensure the prerequisite requirements are complete per Electronic service tool (EST) - H1 - Calibration procedures Calibration Requirements (A.50.A).

2.

Ensure the following conditions are met •

Joysticks in Neutral

•

Proportional Auxiliary Roller Switch in Neutral

•

Key ON

•

Engine ON

•

Hydraulics ON

•

Park Brake Engaged (park brake light on) with the park brake switch, not the OPERATE Button on the IC

•

Hydraulic Oil Temperature between 15 80 °C (59.0 - 176.0 °F)

•

Operator Present

•

Engine RPM less than 1200 RPM

•

No Joystick Related Fault Codes

•

No Loader Related Fault Codes

3.

In the EST configuration menu, open the 'Calibration - Loader Valve' item.

4.

Press the 'SET UP CONTROLLER FOR CALIBRATION' button. •

5.

Press the 'START CALIBRATION' button. •

6.

Ensure 'START CALIBRATION' is now active. Ensure that the text "C-L1" is displayed on the cluster screen.

Move the right joystick to the top right corner (away from the operator) and press and release the loader float button. Keep the right joystick in the top right corner for the entirety of the loader calibration. •

Verify that an audible beep is heard from the instrument cluster and the text "C-L2" is displayed on the cluster screen upon completion of the previous step.

84522361 15/06/2011

A.50.A / 15

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

7.

Keep the right joystick at the top right corner (away from the operator). •

8.

Keep the right joystick at the top right corner (away from the operator). •

9.

Verify that an audible beep is heard from the instrument cluster upon completion of the previous step.

Release the right joystick. •

14.

Verify that an audible beep is heard from the instrument cluster and the text "C-L7" is displayed on the cluster screen upon completion of the previous step.

Keep the right joystick at the top right corner (away from the operator). •

13.

Verify that an audible beep is heard from the instrument cluster and the text "C-L6" is displayed on the cluster screen upon completion of the previous step.

Keep the right joystick at the top right corner (away from the operator). •

12.

Verify that an audible beep is heard from the instrument cluster and the text "C-L5" is displayed on the cluster screen upon completion of the previous step.

Keep the right joystick at the top right corner (away from the operator). •

11.

Verify that an audible beep is heard from the instrument cluster and the text "C-L4" is displayed on the cluster screen upon completion of the previous step.

Keep the right joystick at the top right corner (away from the operator). •

10.

Verify that an audible beep is heard from the instrument cluster and the text "C-L3" is displayed on the cluster screen upon completion of the previous step.

Verify that the EST Calibration Operation Status window says "Calibration Completed Successfully." Verify that the instrument cluster screen returns to normal message display.

Exit out of the Calibration - Loader Valve screen.

84522361 15/06/2011

A.50.A / 16

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

Electronic service tool (EST) - H1 - Calibration procedures Loader Start Pressure Calibration L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

The purpose of the Loader Calibration Procedure is to calibrate the command current to a nominal pressure for each spool and calibrate the neutral position of the loader attachment spool sensors. This is a semi-automatic procedure, therefore most of the operator interaction is via the cluster display screen only. 1.

Ensure the prerequisite requirements are complete per Electronic service tool (EST) - H1 - Calibration procedures Calibration Requirements (A.50.A).

2.

Ensure the following conditions are met •

Joysticks in Neutral

•

Proportional Auxiliary Roller Switch in Neutral

•

Key ON

•

Engine ON

•

Hydraulics ON

•

Park Brake Engaged

•

Hydraulic Oil Temperature between 15 80 °C (59.0 - 176.0 °F)

•

Operator Present

•

Engine RPM less than xxxx RPM

•

Loader Calibration Complete Electronic service tool (EST) - H1 - Calibration procedures Loader Calibration (A.50.A)

•

No Joystick Related Fault Codes

•

No Loader Related Fault Codes

3.

In the EST configuration menu, open the 'Calibration - Loader Start Pressures' item.

4.

Press the 'SET UP CONTROLLER FOR CALIBRATION' button. •

5.

Press the 'START CALIBRATION' button. •

6.

Ensure 'START CALIBRATION' is now active. Ensure that the text "C-S1" is displayed on the cluster screen.

Move the right joystick to the top right corner (away from the operator) and press the loader float button. Keep the right joystick in the top right corner for the entirety of the loader start pressure calibration. •

Verify that an audible beep is heard from the instrument cluster and the text "C-S2" is displayed on the cluster screen upon completion of the previous step.

84522361 15/06/2011

A.50.A / 17

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

7.

Watch for loader raise motion. When detected, immediately toggle that float button. This process is to be repeated tree times for the calibration step. •

8.

Watch for loader lower motion. When detected, immediately toggle that float button. This process is to be repeated tree times for the calibration step. •

9.

Verify that an audible beep is heard from the instrument cluster upon completion of the previous step.

Release the right joystick. •

13.

Verify that an audible beep is heard from the instrument cluster and the text "C-S6" is displayed on the cluster screen upon completion of the previous step.

Watch for bucket curl motion. When detected, immediately toggle that float button. This process is to be repeated tree times for the calibration step. •

12.

Verify that an audible beep is heard from the instrument cluster and the text "C-S5" is displayed on the cluster screen upon completion of the previous step.

Keep the right joystick at the top right corner (away from the operator). •

11.

Verify that an audible beep is heard from the instrument cluster and the text "C-S4" is displayed on the cluster screen upon completion of the previous step.

Watch for bucket dump motion. When detected, immediately toggle that float button. This process is to be repeated tree times for the calibration step. •

10.

Verify that an audible beep is heard from the instrument cluster and the text "C-S3" is displayed on the cluster screen upon completion of the previous step.

Verify that the EST Calibration Operation Status window says "Calibration Completed Successfully." Verify that the instrument cluster screen returns to normal message display.

Exit out of the Calibration - Loader Start Pressures screen.

84522361 15/06/2011

A.50.A / 18

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

Control module Vehical Control Module (VCM) - Remove L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Prior operation: Bucket - Remove (J.20.B) 1.

Raise boom loader.

2.

Engage boom lock out.

3.

Remove left hand side and right hand side cab mounting hardware.

4.

Tilt cab forward and engage cab lock out.

5.

Remove battery cover.

6.

Turn off quick disconnect.

7.

Disconnect negative cable connection.

8.

Remove mounting hardware.

9.

Pull bracket to rear of mounting bolts.

10.

Disconnect upper electrical connections.

11.

Disconnect lower electrical connections.

12.

Remove mounting hardware.

13.

Remove ECM.

84522361 15/06/2011

A.50.A / 19

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

Control module Vehical Control Module (VCM) - Install L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 20

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM

Fuse and relay box - Testing Relay Testing NOTE: See Fuse and relay box Relay - Overview (A.30.A) for general relay information. NOTE: For 4 pin relays follow steps 1-2. For 5 pin relays follow steps 3-5. NOTE: See ELECTRICAL POWER SYSTEM - Component identification Relay Index (A.30.A) for individual relay loads. Test Point N° 1 Condition Relay removed from fuse and relay panel. Check Use a multi-meter to measure the resistance from pin 86 to pin 85. 2 Condition For Normally Open (NO) Relays Check Use a multi-meter to check for continuity between pin 30 to pin 87. 3 Condition Relay removed from fuse and relay panel. Check Use a multi-meter to measure the resistance from pin 86 to pin 85. 4 Condition Relay removed from fuse and panel relay. Check Use a multi-meter to check for continuity between pin 30 to pin 87. 5 Condition Relay removed from fuse and panel relay. Check Use a multi-meter to check for continuity between pin 30 to pin 87a.

Expected Result Other Result (Possible Cause) Result Result There should be approximately 75 - If there is 0.0 Ω or infinite resistance the coil is open or shorted internally. 105 Ω. Action Action Replace the relay. Go to test 2 Result There should be no continuity.

Result If there is continuity, the relay is shorted. Action Replace the relay. Result Result There should be approximately 75 - If there is 0.0 Ω or infinite resistance the coil is open or shorted internally. 105 Ω. Action Action Replace the relay. Go to test 4 Result There should be no continuity. Action Go to test 5

Result If there is continuity, the relay is shorted. Action Replace the relay.

Result There should be continuity.

Result If there is no continuity, the relay is open. Action Replace the relay.

84522361 15/06/2011

A.50.A / 21

Index HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A ELECTRONIC SYSTEM - 50.A Control module Vehical Control Module (VCM) - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control module Vehical Control Module (VCM) - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Data bus - General specification Instrument Cluster pin information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electronic service tool (EST) - H1 - Calibration procedures Calibration Procedure Troubleshooting . . . . . . . . . . . . 8 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electronic service tool (EST) - H1 - Calibration procedures Calibration Requirements . . . . . . . . . . . . . . . . . . . . . . . 7 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electronic service tool (EST) - H1 - Calibration procedures Ground Drive Calibration . . . . . . . . . . . . . . . . . . . . . . . 11 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electronic service tool (EST) - H1 - Calibration procedures Joystick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electronic service tool (EST) - H1 - Calibration procedures Loader Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electronic service tool (EST) - H1 - Calibration procedures Loader Start Pressure Calibration . . . . . . . . . . . . . . . 17 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electronic service tool (EST) - H1 - Calibration procedures Throttle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Electronic service tool (EST) - Overview EST overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuse and relay box - Testing Relay Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

84522361 15/06/2011

A.50.A / 22

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A FAULT CODES - 50.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

A.50.A / 1

Contents HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A FAULT CODES - 50.A

DIAGNOSTIC ELECTRONIC SYSTEM [EGR] - 111-EGR potentiometer valve could not be completely opened . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L223, L225, L230, C227, C232, C238

[EGR] - 112-EGR potentiometer valve could not be completely closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L223, L225, L230, C227, C232, C238

[EGR] - 119-Engine crank signal present for 300 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L223, L225, L230, C227, C232, C238

[EGR] - 126-Battery voltage fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L223, L225, L230, C227, C232, C238

[EGR] - 131-Coolant temperature sensor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 L223, L225, L230, C227, C232, C238

[EGR] - 134-Intake air pressure sensor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 L223, L225, L230, C227, C232, C238

[EGR] - 141-Engine speed sensor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 L223, L225, L230, C227, C232, C238

[EGR] - 186-EGR valve position sensor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 L223, L225, L230, C227, C232, C238

[EGR] - 189-EGR valve position driver fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 L223, L225, L230, C227, C232, C238

[EGR] - 1E5-Sensor voltage supply fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 L223, L225, L230, C227, C232, C238

[EGR] - 2E5-Sensor ground fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 L223, L225, L230, C227, C232, C238

[IC] - 1002- Engine Coolant Temperature Sender - Over Temperature >110° C . . . . . . . . . . . . . . . . . . . . 44 [IC] - 1004- Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted . . . . . . . . . . . . . . . . . . . . . . . . 45 [IC] - 1009- Hydraulic Oil Temperature Sender - Over Temperature >210° F . . . . . . . . . . . . . . . . . . . . . . . 46 [IC] - 1014- Cluster Battery Monitor - Over Voltage > 16.5 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 [IC] - 1015-Cluster Battery Monitor - Under Voltage < 11.5 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 [IC] - 1041- RPM Monitoring - Over Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 [IC] - 1045- Fuel Level Sensor - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 [IC] - 1201- Hydraulic Filter Restriction Switch - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 [IC] - 1202- RPM Monitoring - Over Speed (Max) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 [IC] - 1203- RPM Monitoring - Open Circuit / STG / STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 [IC] - 1204- Start Sequence - Key Switch State - Engine Running Plausability Fault . . . . . . . . . . . . . . . . 62

84522361 15/06/2011

A.50.A / 2

[IC] - 1205- Hydraulic Enable (EH Machines) - Hydraulic Enable Output - STP . . . . . . . . . . . . . . . . . . . . 64 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[IC] - 1208- Seat Switch - Plausibility Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[IC] - 3000- Engine Malfunction - ECU Fault - General/Undefined/Air Filter Restriction . . . . . . . . . . . . . . 68 [IC] - 3007- Engine Coolant Temperature Sender - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 [IC] - 3008- Engine Coolant Temperature Sender - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 [IC] - 3028- Engine Oil Pressure Switch - Engine Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 [IC] - 3029- Engine Oil Pressure Switch - Engine Oil Pressure Switch OC . . . . . . . . . . . . . . . . . . . . . . . . . 76 [IC] - 3156- Engine Preheat - Glow Plug - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 [IC] - 3401- Engine Start - Fuel Solenoid - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 [IC] - 3402- Engine Start - Fuel Solenoid - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 [IC] - 3403- Starter - Starter is cranked > 30s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 [IC] - 3404- Starter - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 [IC] - 3405- Starter - STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 [IC] - 4043- Hydraulic Oil Temperature Sender - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 [IC] - 4044- Hydraulic Oil Temperature Sender - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 [IC] - 4401- Park Brake (Mechanical Machines) - Park Brake Solenoid - OC . . . . . . . . . . . . . . . . . . . . . . . 95 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

[IC] - 4402- Park Brake (Mechanical Machines) - Park Brake Solenoid - STP . . . . . . . . . . . . . . . . . . . . . . 97 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

[IC] - 4951- Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid - STP . . . . . . . . . . 98 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

[IC] - 4952- Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid - OC . . . . . . . . . . 100 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

[IC] - 5503- Hydraulic Enable (Mechanical Machines) - EH AUX Output - STP . . . . . . . . . . . . . . . . . . . . 102 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

[IC] - 9003- CAN - J1939 Receive Buffer - Buffer Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 [IC] - 9004- Memory Error - Triple Redundant - Hour Meter - Location 1 Corrupt . . . . . . . . . . . . . . . . . . 105 [IC] - 9005- Memory Error - Triple Redundant - Hour Meter - Location 2 Corrupt . . . . . . . . . . . . . . . . . . 106 [IC] - 9006- Memory Error - Triple Redundant - Hour Meter - Location 3 Corrupt . . . . . . . . . . . . . . . . . . 107 [IC] - 9401- Memory Error - Double Redundant - Memory Corruption Detected and repaired . . . . . . . 108 [IC] - 9403- Memory Error - Double Redundant - Un-recoverable memory corruption operable . . . . . . 109 [IC] - 9404- Memory Error - Triple Redundant - Hour Meter - Hour Meter Failure . . . . . . . . . . . . . . . . . . 110 [IC] - 9405- CAN - DM1 (EH Machines) - Loss of DM1 message from UCM . . . . . . . . . . . . . . . . . . . . . . 111 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 3

[IC] - 9406- CAN - Can Communication Lost (EH Machines) - Loss of all can communication from UCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[IC] - 9407- Memory Error - ID Errors - Unrecoverable Hardware ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 [IC] - 9408- Memory Error - ID Errors - Unrecoverable Panel ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 [UCM] - 1025- Throttle Sensor - out of range STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1030- Throttle Sensor - out of range STG/OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1206- CAN Connection - Configuration Response Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1207- Memory Parameters - Invalid configuration between IC and UCM . . . . . . . . . . . . . . . . . 123 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1211- Calibration Functions - Joystick Calibration not Complete . . . . . . . . . . . . . . . . . . . . . . . . . 124 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1212- Calibration Functions - Ground Drive Calibration not Complete . . . . . . . . . . . . . . . . . . . . 125 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1213- Calibration Functions - Loader Valve Calibration not Complete . . . . . . . . . . . . . . . . . . . . 126 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1214- Calibration Functions - Throttle Calibration not Complete . . . . . . . . . . . . . . . . . . . . . . . . . 127 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1221- Health Monitor Functions - UCM - UCM Temperature / Current Draw Over Limit . . . . . 128 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1222- Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit . . . . . . . . . 129 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1223- Health Monitor Functions - UCM - UCM Sustained Over Current Limit . . . . . . . . . . . . . . 130 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1224- Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault . . . . . . . . 131 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1225- Health Monitor Functions - UCM - EEPROM Memory Checksum Fault . . . . . . . . . . . . . 132 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 4

[UCM] - 1350- Hyd Ena switch - Implausible State (Hardwire vs CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1511- Brake Lights - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

[UCM] - 1512- Brake Lights - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

[UCM] - 1513- Brake Lights - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

[UCM] - 1521- Brake Lights - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

[UCM] - 1522- Brake Lights - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

[UCM] - 1523- Brake Lights - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

[UCM] - 1532- Backup Alarm - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1533- Backup Alarm - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1900- UCM - UCM Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1901- UCM - UCM Supply Voltage HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1902- UCM - UCM Supply Voltage LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1904- UCM - Rail 12VB - 5V regulators supply Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . 153 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1905- UCM - 5VREF1 Sensor Supply Voltage Out of Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 5

[UCM] - 1906- UCM - 5VREF3 Sensor Supply Voltage Out of Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1907- UCM - Rail 12VF1 - Aux Retract Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1908- UCM - Rail 12VF2 - Bucket Extend Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1909- UCM - Rail 12VF3 - Boom Raise/Lower Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . 161 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1911- UCM - Rail 12VH1 - Left & Right Pmp Reverse Input Power OFF . . . . . . . . . . . . . . . . . . 163 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1912- UCM - Rail 12VM - Lft & Rgt Brake Lights & Aux Extend Input Power OFF . . . . . . . . . . 165 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1913- UCM - Rail 12VS1 - Bucket Curl Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1914- UCM - Rail 12VS2 - Backup Alarm Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1915- UCM - Rail 12VT1 - Two Speed Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1916- UCM - Rail 12VU1 - Right & Left Pumps Forward Input Power OFF . . . . . . . . . . . . . . . . 173 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 1917- UCM - Rail 12VU2 - Park Brake Solenoid Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . 175 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 3154- Engine Preheat - Glow Plug - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 [UCM] - 4055- Park Brake Valve (On/Off) - Solenoid Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4056- Park Brake Valve (On/Off) - Solenoid Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4057- Park Brake Valve (On/Off) - Solenoid Supply STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4061- Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply OC . . . . . . . . . 184 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 6

[UCM] - 4062- Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply STG . . . . . . . . 186 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4071- Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply OC . . . . . . . . . . 188 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4072- Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply STG . . . . . . . . . 190 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4081- Forward Pump Control Valves (Directional) - Common Solenoid Return STP . . . . . . . . 192 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4082- Forward Pump Control Valves (Directional) - Pumps Forward Solenoids STG . . . . . . . 194 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4083- Forward Pump Control Valves (Directional) - Common Solenoid Return OC . . . . . . . . . 196 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4309- Park Brake Button - Park Brake Button Timeout (30 sec) . . . . . . . . . . . . . . . . . . . . . . . . . 197 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4361-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply OC . . . . . . . . . 198 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4362- Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply STG . . . . . . . . 200 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4371- Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply OC . . . . . . . . . . 202 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4372- Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply STG . . . . . . . . . 204 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4381- Reverse Pump Control Valves (Directional) - Common Solenoid Return STP . . . . . . . . 206 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4382- Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids STG . . . . . . . 208 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4383- Reverse Pump Control Valves (Directional) - Common Solenoid Return OC . . . . . . . . . 210 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4431- Park Brake Pressure Switch - Pressure Switch (plausibility check with solenoid valve) 212 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 7

[UCM] - 4731- Right Swashplate angle sensor - Pin A STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4732- Right Swashplate angle sensor - Pin A STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4734- Right Swashplate angle sensor - Pin B STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4735- Right Swashplate angle sensor - Pin B STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4737- Right Swashplate angle sensor - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4741- Left Swashplate angle sensor - Pin A STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4742- Left Swashplate angle sensor - Pin A STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4744- Left Swashplate angle sensor - Pin B STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4745- Left Swashplate angle sensor - Pin B STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4747- Left Swashplate angle sensor - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4752- Left Swashplate angle sensor - Implausible command, command does not match with swashplate angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4754- Right Swashplate angle sensor - Implausible command, command does not match with swashplate angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4781- solenoid valve - Solenoid Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4782- solenoid valve - Solenoid Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 4783- solenoid valve - Solenoid Supply STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 8

[UCM] - 5051- Loader Pilot Interlock Valve (On/Off) - Solenoid Supply OC . . . . . . . . . . . . . . . . . . . . . . . 241 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5052- Loader Pilot Interlock Valve (On/Off) - Solenoid Supply STG . . . . . . . . . . . . . . . . . . . . . . 243 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5053- Loader Pilot Interlock Valve (On/Off) - Solenoid Supply STP . . . . . . . . . . . . . . . . . . . . . . 245 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5061- Port Lock Valve (On/Off) - Solenoid Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5062- Port Lock Valve (On/Off) - Solenoid Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5063- Port Lock Valve (On/Off) - Solenoid Supply STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5121-R joy F-B axis - Pin A STP / STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5122- R joy F-B axis - Pin B STP / STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5124- R joy F-B axis - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5131- R joy R-L axis (ISO/H Pattern) - Pin A STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5132- R joy R-L axis (ISO/H Pattern) - Pin A STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5134- R joy R-L axis (ISO/H Pattern) - Pin B STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5135- R joy R-L axis (ISO/H Pattern) - Pin B STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5137- R joy R-L axis (ISO/H Pattern) - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5141- Aux thumbwheel axis - Pin A STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 9

[UCM] - 5142- Aux thumbwheel axis - Pin A STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5144- Aux thumbwheel axis - Pin B STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5145-Aux thumbwheel axis - Pin B STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5147- Aux thumbwheel axis - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5201- L joystick L-R axis - Pin A STP / STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5202- L joystick L-R axis - Pin B STP / STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5204-L joystick L-R axis - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5211- L joy F-B axis - Pin A STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5212- L joy F-B axis - Pin A STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5214-L joy F-B axis - Pin B STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5215- L joy F-B axis - Pin B STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5217- L joy F-B axis - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5221- Loader Arm Valve (Directional) - Solenoid Raise A Supply OC . . . . . . . . . . . . . . . . . . . . 292 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5222- Loader Arm Valve (Directional) - Solenoid Raise A Supply STG . . . . . . . . . . . . . . . . . . . 294 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5231- Loader Arm Valve (Directional) - Solenoid Lower B Supply OC . . . . . . . . . . . . . . . . . . . . 296 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 10

[UCM] - 5232- Loader Arm Valve (Directional) - Solenoid Lower B Supply STG . . . . . . . . . . . . . . . . . . . 298 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5241- Boom Valve (Directional) - Common Solenoid (C) Return STP . . . . . . . . . . . . . . . . . . . . 300 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5242- Loader Arm Valve (Directional) - Loader Arm Solenoids STG . . . . . . . . . . . . . . . . . . . . . 302 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5243- Boom Valve (Directional) - Common Solenoid (C) Return OC . . . . . . . . . . . . . . . . . . . . . 304 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5251- Loader Bucket Valve (Directional) - Solenoid rollback (A) Supply OC . . . . . . . . . . . . . . . 306 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5252- Loader Bucket Valve (Directional) - Solenoid rollback (A) Supply STG . . . . . . . . . . . . . . 308 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5261- Bucket Valve (Directional) - Solenoid dump (B) Supply OC . . . . . . . . . . . . . . . . . . . . . . . 310 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5262- Bucket Valve (Directional) - Solenoid dump (B) Supply STG . . . . . . . . . . . . . . . . . . . . . . 312 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5271- Bucket Valve (Directional) - Common Solenoid (C) Return STP . . . . . . . . . . . . . . . . . . . 314 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5272- Loader Bucket Valve (Directional) - Loader Bucket Solenoids STG . . . . . . . . . . . . . . . . . 316 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5273- Bucket Valve (Directional) - Common Solenoid (C) Return OC . . . . . . . . . . . . . . . . . . . . 318 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5281- Aux Valve (Directional) - Solenoid Forward (A) Supply OC . . . . . . . . . . . . . . . . . . . . . . . . 320 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5282- Aux Valve (Directional) - Solenoid Forward (A) Supply STG . . . . . . . . . . . . . . . . . . . . . . . 322 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5291- Aux Valve (Directional) - Solenoid Reverse (B) Supply OC . . . . . . . . . . . . . . . . . . . . . . . . 324 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5292- Aux Valve (Directional) - Solenoid Reverse (B) Supply STG . . . . . . . . . . . . . . . . . . . . . . . 326 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 11

[UCM] - 5309- Float Button - Float Button Timeout (30 sec) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5409- CAN Message Error - Aux Override Disabled due to Aux Override Button Timeout (30 sec) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5501- Loader Arm Spool Sensor - Sensor STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5502- Loader Arm Spool Sensor - Sensor STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5504- Bucket Valve Spool sensor - Sensor STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5505- Bucket Valve Spool sensor - Sensor STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5507-Auxiliary Valve Spool Sensor - Sensor STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5508- Auxiliary Valve Spool Sensor - Sensor STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5511- Loader Arm Spool Sensor - implausible state sensor vs loader arm command, stuck spool/ PRV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5512- Bucket Valve Spool sensor - implausible state sensor vs loader bucket command . . . 344 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5513- Auxiliary Valve Spool Sensor - implausible state sensor vs auxiliary command . . . . . . 346 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5601- Aux Valve (Directional) - Common Solenoid Return STP . . . . . . . . . . . . . . . . . . . . . . . . . 348 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5602- Loader Auxiliary Valve (Directional) - Loader Auxiliary Solenoids STG . . . . . . . . . . . . . . 350 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5603- Loader Auxiliary Valve (Directional) - Solenoids Return OC . . . . . . . . . . . . . . . . . . . . . . . 352 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5701- Pattern Switch - STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 12

[UCM] - 5703- Pattern Switch - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 5811- switch - implausible state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

[UCM] - 9151- CAN Connection - CAN communication timed out after 5 seconds . . . . . . . . . . . . . . . . . 361 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 9152-CAN connection - CAN communication timed out after 5 seconds . . . . . . . . . . . . . . . . . . 364 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 9158- H pattern indicator - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 9159- ISO pattern indicator - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 9160- H pattern indicator - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCM] - 9161- ISO pattern indicator - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCm] - 1903- UCM - UCM Supply Voltage Below Operational Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

[UCm] - 1910- UCM - Rail 12VH - Ldr Plt Interlk & Port Lock Input Power OFF . . . . . . . . . . . . . . . . . . . 375 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 13

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

111-EGR potentiometer valve could not be completely opened L223, L225, L230, C227, C232, C238

Control Module : EGR NOTE: The Electronic Service Tool must be used to remove faults from memory. NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical system NOTE: If faults are present in the EST but engine fault lamp is not illuminated, check diagnostic lamp fault line for open circuits. Cause: 1.

Faulty reading from component.

2.

Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.

3.

Wiring or circuits open.

4.

Wiring or circuits shorted.

5.

Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean socket terminals by removing and then reinstalling connector.

Solution: 1.

Use the Electronic Service Tool to check fault status on the Controller Faults page. If Fault 111 is active go to step 2. Clear all fault codes and check for reoccurrence. (1) To check for fault code: (a.) Run valve control test on EST. (a1.) Go to CONTROLLER TEST screen. (a2.) Activate START TEST button. (a3.) Activate ENABLE button. (a4.) Move EGR Valve Control Slider to 100%. (a5.) EGR Potentiometer Feedback Signal and EGR Pot Calibration – Higher Stroke should match within 2%.

2.

A.

NOT OK – EGR Potentiometer Feedback Signal does not match EGR Pot Calibration – Higher Stroke: EGR valve is not opening correctly. Replace EGR valve if obstruction is not found with step 3 procedure. Exit test screen on EST and go to step 3.

B.

NOT OK – EGR Potentiometer Feedback Signal does not change with EST command: Exit test screen on EST and go to step 4 to check harnesses related to the EGR valve.

C.

OK – Exit test screen and continue to step 2.

Test the EGR valve by operating machine (1) Start engine and run at full throttle for at least 4 seconds. (2) Run engine at low throttle for at least 4 seconds. (3) Repeat 1 and 2 ten (10) times.

3.

A.

NOT OK – Fault code 111 is recorded again. Go to Step 3.

B.

OK – Fault is not recorded again. OK for return to service.

Inspect the EGR valve.

84522361 15/06/2011

A.50.A / 14

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

BD08F227-01

1

(1) Remove the EGR valve from the machine. (2) Check the EGR valve for obstructions.

4.

A.

NOT OK – Replace EGR valve. Return to Step 2 to confirm elimination of fault.

B.

OK – Go to Step 4.

Disconnect the connectors at the EGR controller and the EGR valve. (1) Test circuit for continuity from pin 1 X-EGR controller connector, to pin 1 at EGR valve , a reading of continuity should be obtained. (2) Test circuit for continuity from pin 8 X-EGR controller connector, to pin 2 at EGR valve, a reading of continuity should be obtained. (3) Test circuit for continuity from pin 10 X-EGR controller connector, to pin 4 at EGR valve, a reading of continuity should be obtained. (4) Test circuit for continuity from pin 3 X-EGR controller connector, to pin 5 at EGR valve, a reading of continuity should be obtained. (5) Test circuit for continuity from pin 19 X-EGR controller connector, to pin 6 at EGR valve, a reading of continuity should be obtained.

5.

A.

NOT OK – Go to Step 5.

B.

OK – Go to Step 6.

Disconnect connector from EGR harness to engine EGR harness.

BD08F228-01

2

(1) Test circuit for continuity from pin 1 X-EGR controller connector, to pin 1A at X-FPT connector, a reading of continuity should be obtained. (2) Test circuit for continuity from pin 8 X-EGR controller connector, to pin 3A at X-FPT connector, a reading of continuity should be obtained. 84522361 15/06/2011

A.50.A / 15

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

(3) Test circuit for continuity from pin 10 X-EGR controller connector, to pin 5A at X-FPT connector, a reading of continuity should be obtained. (4) Test circuit for continuity from pin 3 X-EGR controller connector, to pin 1B at X-FPT connector, a reading of continuity should be obtained. (5) Test circuit for continuity from pin 19 X-EGR controller connector, to pin 4A at X-FPT connector, a reading of continuity should be obtained. (6) Test circuit for continuity from pin 1A at X-FPT connector to pin 1 at EGR valve, a reading of continuity should be obtained. (7) Test circuit for continuity from pin 3A at X-FPT connector to pin 2 at EGR valve, a reading of continuity should be obtained. (8) Test circuit for continuity from pin 5A at X-FPT connector to pin 4 at EGR valve, a reading of continuity should be obtained. (9) Test circuit from pin 1B at X-FPT connector to pin 5 at EGR valve, a reading of continuity should be obtained. (10) Test circuit for continuity from pin 4A at X-FPT connector to pin 6 at EGR valve , a reading of continuity should be obtained.

6.

A.

NOT OK – Repair or replace harness as needed. Return to Step 2 to confirm elimination of fault.

B.

OK – Go to Step 6.

Replace EGR valve, A.

7.

Return to Step 2 to confirm elimination of fault. If fault is recorded again, go to Step 7.

Replace EGR controller. A.

Return to Step 2 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group for assistance. Wiring harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) Wiring harness - Electrical schematic frame 99 (A.30.A.88-C.20.E.99)

84522361 15/06/2011

A.50.A / 16

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

112-EGR potentiometer valve could not be completely closed L223, L225, L230, C227, C232, C238

Control Module : EGR NOTE: The Electronic Service Tool must be used to remove faults from memory. NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical system NOTE: If faults are present in the EST but engine fault lamp is not illuminated, check diagnostic lamp fault line for open circuits. Cause: 1.

Faulty reading from component.

2.

Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.

3.

Wiring or circuits open.

4.

Wiring or circuits shorted.

5.

Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean socket terminals by removing and then reinstalling connector.

Solution: 1.

Use the Electronic Service Tool to check fault status on the Controller Faults page. If Fault 112 is active go to step 2. Clear all fault codes and check for reoccurrence. (1) To check for fault code: (a.) Run valve control test on EST. (a1.) Go to CONTROLLER TEST screen. (a2.) Activate START TEST button. (a3.) Activate ENABLE button (a4.) Move EGR Valve Control Slider to 0%. (a5.) EGR Potentiometer Feedback Signal and EGR Pot Calibration – Lower Stroke should match within 2%.

2.

A.

NOT OK – EGR Potentiometer Feedback Signal does not match EGR Pot Calibration – Lower Stroke: EGR valve is not closing correctly. Replace EGR valve if obstruction is not found with step 3 procedure. Exit test screen on EST and go to step 3.

B.

NOT OK – EGR Potentiometer Feedback Signal does not change with EST command: Exit test screen on EST and go to step 4 to check harnesses related to the EGR valve.

C.

OK – Exit test screen and continue to step 2.

Test the EGR valve by operating machine (1) Start engine and run at full throttle for at least 4 seconds. (2) Run engine at low throttle for at least 4 seconds. (3) Repeat 1 and 2 ten (10) times.

3.

A.

NOT OK – Fault code 112 is recorded again. Go to Step 3.

B.

OK – Fault is not recorded again. OK for return to service.

Inspect the EGR valve.

84522361 15/06/2011

A.50.A / 17

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

BD08F227-01

1

(1) Remove the EGR valve from the machine. (2) Check the EGR valve for obstructions.

4.

A.

NOT OK – Replace EGR valve. Return to Step 2 to confirm elimination of fault.

B.

OK – Go to Step 4.

Disconnect the connectors at the EGR controller and the EGR valve. (1) Test circuit for continuity from pin 1 X-EGR controller connector to pin 1 at EGR valve connector, a reading of continuity should be obtained. (2) Test circuit for continuity from pin 8 X-EGR controller connector to pin 2 at EGR valve connector, a reading of continuity should be obtained. (3) Test circuit for continuity from pin 10 X-EGR controller connector to pin 4 at EGR valve connector, a reading of continuity should be obtained. (4) Test circuit for continuity from pin 3 X-EGR controller connector to pin 5 at EGR valve connector, a reading of continuity should be obtained. (5) Test circuit for continuity from pin 19 X-EGR controller connector to pin 6 at EGR valve connector, a reading of continuity should be obtained.

5.

A.

NOT OK – Go to Step 5.

B.

OK – Go to Step 6.

Disconnect connector from EGR harness to engine EGR harness.

BD08F228-01

2

(1) Test circuit for continuity from pin 1 X-EGR controller connector to pin 1A at X-FPT connector, a reading of continuity should be obtained. (2) Test circuit for continuity from pin 8 X-EGR controller connector to pin 3A at X-FPT connector, a reading of continuity should be obtained. 84522361 15/06/2011

A.50.A / 18

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

(3) Test circuit for continuity from pin 10 X-EGR controller connector to pin 5A at X-FPT connector, a reading of continuity should be obtained. (4) Test circuit for continuity from pin 3 X-EGR controller connector to pin 1B at X-FPT connector, a reading of continuity should be obtained. (5) Test circuit for continuity from pin 19 X-EGR controller connector to pin 4A at X-FPT connector, a reading of continuity should be obtained. (6) Test circuit for continuity from pin 1A at X-FPT connector to pin 1 at EGR valve connector, a reading of continuity should be obtained. (7) Test circuit for continuity from pin 3A at X-FPT connector to pin 2 at EGR valve connector, a reading of continuity should be obtained. (8) Test circuit for continuity from pin 5A at X-FPT connector to pin 4 at EGR valve connector, a reading of continuity should be obtained. (9) Test circuit from pin 1B at X-FPT connector to pin 5 at EGR valve connector, a reading of continuity should be obtained. (10) Test circuit for continuity from pin 4A at X-FPT connector to pin 6 at EGR valve connector, a reading of continuity should be obtained.

6.

A.

NOT OK – Repair or replace harness as needed. Return to Step 2 to confirm elimination of fault.

B.

OK – Go to Step 6.

Replace EGR valve, A.

7.

Return to Step 2 to confirm elimination of fault. If fault is recorded again, go to Step 7.

Replace EGR controller. A.

Return to Step 2 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group for assistance. Wiring harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) Wiring harness - Electrical schematic frame 99 (A.30.A.88-C.20.E.99)

84522361 15/06/2011

A.50.A / 19

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

119-Engine crank signal present for 300 seconds L223, L225, L230, C227, C232, C238

Control Module : EGR NOTE: The Electronic Service Tool must be used to remove faults from memory. NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical system NOTE: If faults are present in the EST but engine fault lamp is not illuminated, check diagnostic lamp fault line for open circuits. Cause: 1.

Faulty reading from component.

2.

Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.

3.

Wiring or circuits open.

4.

Wiring or circuits shorted.

5.

Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean socket terminals by removing and then reinstalling connector.

Solution: 1.

Use the Electronic Service Tool to check fault status on the Controller Faults page. If Fault 119 is active go to step 2. Clear all fault codes and check for reoccurrence. (1). To check for fault code: Start and operate machine for at least 6 minutes.

2.

A.

NOT OK – Fault code 119 is recorded again. Go to Step 2.

B.

OK – Fault is not recorded again. OK for return to service.

Disconnect the connector at the EGR controller.

BD08F234-01

1

(1) Turn the ignition switch to the run position, check for voltage at pin 5 at the X-EGR controller connector, no voltage should be present. (2) Continue to take a voltage reading at pin 5, turn the ignition switch to the start position, a reading of battery voltage should be obtained. (3) Continue to take a voltage reading at pin 5, with the engine running, no voltage should be present.

3.

A.

NOT OK – Go to Step 3.

B.

OK – Go to Step 6.

Disconnect the connector from the EGR harness to the main engine harness. 84522361 15/06/2011

A.50.A / 20

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

BD08F230-01

2

(1) Test circuit for continuity from pin 3 of the X-EGR controller connector to pin 4 of the X-FPT (also see connector X-FPT) harness connector, a reading of continuity should be obtained. (2) Test circuit for continuity from pin 18 of the X-EGRcontroller connector to pin 3 of the X-FPT (also see connector X-FPT) harness connector, a reading of continuity should be obtained.

4.

A.

NOT OK – Repair or replace harness as needed. Return to Step 1 to confirm elimination of fault.

B.

OK – Go to Step 4.

Tilt the seat to gain access to connector 8 and do the following test on the engine harness.

BD08G019-02

3

(1) Test grounding circuit for continuity at pin 4 of the X-FPT (also see connector X-FPT) connector, a reading of continuity should be obtained. (2) Test circuit for continuity from pin 3 of the X-FPT (also see connector X-FPT) wire 625 on starter solenoid or at connector to pin 10 on the main chassis harness connector 8, a reading of continuity should be obtained. (3) Test circuit for continuity from pin 1 of the X-FPT (also see connector X-FPT) wire 625 on starter solenoid or at connector to pin 10 on the main chassis harness connector 8, the circuit should be open. (4) Test circuit for continuity from pin 2 of the X-FPT connector (also see connector X-FPT) wire 625 on starter solenoid or at connector to pin 10 on the main chassis harness connector 8, the circuit should be open.

5.

6.

A.

NOT OK – Repair or replace harness as needed. Return to Step 1 to confirm elimination of fault.

B.

OK – Go to Step 5.

Check machine starting system, fuses and ignition switch. A.

NOT OK – Repair starting system as needed. Return to Step 1 to confirm elimination of fault.

B.

OK – Go to Step 6.

Replace EGR controller.

84522361 15/06/2011

A.50.A / 21

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

A.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group for assistance.

84522361 15/06/2011

A.50.A / 22

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

126-Battery voltage fault L223, L225, L230, C227, C232, C238

Control Module : EGR NOTE: The Electronic Service Tool must be used to remove faults from memory. NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical system NOTE: If faults are present in the EST but engine fault lamp is not illuminated, check diagnostic lamp fault line for open circuits. Cause: 1.

Faulty reading from component.

2.

Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.

3.

Wiring or circuits open.

4.

Wiring or circuits shorted.

5.

Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean socket terminals by removing and the reinstalling connector.

Solution: 1.

2.

Use the Electronic Service Tool to check battery voltage on Monitoring page. Voltage should be 9.5 - 16.5 V. A.

NOT OK – Voltage is out of range. Go to Step 3

B.

OK – Voltage is in range. Clear all fault codes on EST and go to step 2.

Check for reoccurrence of fault. (1). To check for fault code: Start and operate machine for at least 2 seconds.

3.

4.

A.

NOT OK – Fault code 126 is recorded again. Go to Step 3.

B.

OK – Fault is not recorded again. OK for return to service.

Check machine charging system, fuses and ignition switch. A.

NOT OK – Repair charging system as needed. Return to Step 2 to confirm elimination of fault.

B.

OK – Go to Step 4.

Disconnect the connector at the EGR controller and turn the ignition switch to the ON position. (1) Check for voltage at pin 14 X-EGR connector to ground, a reading of battery voltage should be obtained. (2) Check for voltage at pin 5 X-EGR connector to ground, a reading of battery voltage should be obtained. (3) Take a continuity reading at pin 3 X-EGR connector to ground, a reading of continuity should be obtained.

5.

A.

NOT OK – Go to Step 5.

B.

OK – Go to Step 6.

Disconnect connector from EGR harness to the main engine harness.

84522361 15/06/2011

A.50.A / 23

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

BD08F230-01

1

(1) Take a continuity reading from pin 14 X-EGR connector to pin 1 at X-FPT connector (see also connector X-FPT), a reading of continuity should be obtained. (2) Take a continuity reading from pin 5 X-EGR connector to pin 2 at X-FPT connector (see also connector X-FPT), a reading of continuity should be obtained. (3) Take a continuity reading from pin 3 X-EGR connector to pin 4 at X-FPT connector (see also connector X-FPT), a reading of continuity should be obtained. (4) Take a continuity reading from pin 1 at X-FPT connector (see also connector X-FPT) to fuse F2, a reading of continuity should be obtained, check fuse. (5) Test circuit from pin 2 at X-FPT connector (see also connector X-FPT) to fuse F3, a reading of continuity should be obtained, check fuse and ignition switch. (6) Test circuit from pin 4 at X-FPT connector (see also connector X-FPT) to ground, a reading of continuity should be obtained.

6.

A.

NOT OK – Repair or replace harness as needed. Return to Step 2 to confirm elimination of fault.

B.

OK – Go to Step 6.

Replace EGR controller. A.

Return to Step 2 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group for assistance.

84522361 15/06/2011

A.50.A / 24

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

131-Coolant temperature sensor fault L223, L225, L230, C227, C232, C238

Control Module : EGR NOTE: The Electronic Service Tool must be used to remove faults from memory. NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical system NOTE: If faults are present in the EST but engine fault lamp is not illuminated, check diagnostic lamp fault line for open circuits. Cause: 1.

Faulty reading from component.

2.

Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.

3.

Wiring or circuits open.

4.

Wiring or circuits shorted.

5.

Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean socket terminals by removing and then reinstalling connector.

Solution: 1.

Use the Electronic Service Tool to check fault status on the Controller Faults page. If Fault 131 is active go to step 2. Clear all fault codes and check for reoccurrence. (1). Check for fault code by leaving key on for at least two (2) seconds.

2.

A.

NOT OK – Fault code 131 is recorded again. Go to Step 2.

B.

OK – Fault is not recorded again. OK for return to service.

Disconnect connector at temperature sensor.

BD08F236-01

1

(1) Turn ignition switch on, check for voltage at pin A at Coolant temperature sensor sensor, a reading of approximately 5 V should be obtained.

3.

A.

NOT OK – Go to Step 3.

B.

OK – Go to Step 5.

Disconnect the connector at the EGR controller. (1) Take a continuity reading from pin 20 X-EGR controller connector to pin A at Coolant temperature sensor, a reading of continuity should be obtained.

84522361 15/06/2011

A.50.A / 25

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

(2) Take a continuity reading from pin 11 X-EGR controller connector to pin C at Coolant temperature sensor, a reading of continuity should be obtained.

4.

A.

NOT OK – Go to Step 4.

B.

OK – Go to Step 5.

Disconnect connector from EGR harness to engine EGR harness.

BD08F228-01

2

(1) Take a continuity reading from pin 11 X-EGR controller connector to pin 4B at X-FPT connector, a reading of continuity should be obtained. (2) Take a continuity reading from pin 20 X-EGR controller connector to pin 5B at X-FPT connector, a reading of continuity should be obtained. (3) Take a continuity reading from pin 4B at X-FPT connector to pin C at Coolant temperature sensor, a reading of continuity should be obtained. (4) Take a continuity reading from pin 5B at X-FPT connector to pin A at Coolant temperature sensor, a reading of continuity should be obtained.

5.

A.

NOT OK – Repair or replace harness as needed. Return to Step 1 to confirm elimination of fault.

B.

OK – Go to Step 5.

Replace coolant temperature sensor. A.

6.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, go to Step 6.

Replace EGR controller. A.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group for assistance. Wiring harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) Wiring harness - Electrical schematic frame 99 (A.30.A.88-C.20.E.99)

84522361 15/06/2011

A.50.A / 26

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

134-Intake air pressure sensor fault L223, L225, L230, C227, C232, C238

Control Module : EGR NOTE: The Electronic Service Tool must be used to remove faults from memory. NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical system NOTE: If faults are present in the EST but engine fault lamp is not illuminated, check diagnostic lamp fault line for open circuits. Cause: 1.

Faulty reading from component.

2.

Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.

3.

Wiring or circuits open.

4.

Wiring or circuits shorted.

5.

Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean socket terminals by removing and then reinstalling connector.

Solution: 1.

Use the Electronic Service Tool to check fault status on the Controller Faults page. If Fault 134 is active go to step 2. Clear all fault codes and check for reoccurrence. (1). Check for fault code by leaving key on for at least two (2) seconds.

2.

A.

NOT OK – Fault code 134 is recorded again. Go to Step 2.

B.

OK – Fault is not recorded again. OK for return to service.

Place ignition switch in the RUN position, monitor screen on EST. (1) Pressure reading above 296.5 kPa (43 psi) means a short to power or open circuit on the sensor. (2) Pressure reading less than 20.7 kPa (3 psi) means a short to ground on the sensor. A.

Go to Step 3.

NOTE: Procedures in Step 2 are done to see if there is a short circuit. 3.

Disconnect connector at boost pressure-temperature sensor.

BD08F236-01

1

(1) Turn ignition switch on, check for voltage at pin 3 at Boost pressure/temperature sensor, a reading of approximately 5 V should be obtained. A.

NOT OK – Go to Step 4. 84522361 15/06/2011

A.50.A / 27

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 4.

OK – Go to Step 6.

Disconnect the connector at the EGR controller. (1) Take a continuity reading from pin 12 X-EGR to pin 1 at Boost pressure/temperature sensor, a reading of continuity should be obtained. (2) Take a continuity reading from pin 21 X-EGR to pin 2 at Boost pressure/temperature sensor, a reading of continuity should be obtained. (3) Take a continuity reading from pin 7 X-EGR to pin 3 at Boost pressure/temperature sensor, a reading of continuity should be obtained. (4) Take a continuity reading from pin 22 X-EGR to pin 4 at Boost pressure/temperature sensor, a reading of continuity should be obtained. (5) Take a continuity reading from pin 22 X-EGR to pin 3 at X-EGR, circuit should be open. (6) Take a continuity reading from pin 5 X-EGR to pin 14 at X-EGR, circuit should be open.

5.

A.

NOT OK – Go to Step 5.

B.

OK – Go to Step 6.

Disconnect connector from EGR harness to engine EGR harness.

BD08F228-01

2

(1) Take a continuity reading from pin 12 X-EGR to pin 6A at X-FPT connector, a reading of continuity should be obtained. (2) Take a continuity reading from pin 21 X-EGR to pin 3B at X-FPT connector, a reading of continuity should be obtained. (3) Take a continuity reading from pin 7 X-EGR to pin 2B at X-FPT connector, a reading of continuity should be obtained. (4) Take a continuity reading from pin 22 X-EGR to pin 7A at X-FPT connector, a reading of continuity should be obtained. (5) Take a continuity reading from pin 6A at X-FPT connector to pin 1 at Boost pressure/temperature sensor, a reading of continuity should be obtained. (6) Take a continuity reading from pin 3B at X-FPT connector to pin 2 at Boost pressure/temperature sensor, a reading of continuity should be obtained. (7) Take a continuity reading from pin 2B at X-FPT connector to pin 3 at Boost pressure/temperature sensor, a reading of continuity should be obtained. (8) Take a continuity reading from pin 7A at X-EGR connector to pin 4 at Boost pressure/temperature sensor, a reading of continuity should be obtained. (9) Take a continuity reading from pin 7A X-EGR to pin 6A at X-EGR, circuit should be open. 84522361 15/06/2011

A.50.A / 28

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

A.

NOT OK – Repair or replace harness as needed. Return to Step 1 to confirm elimination of fault.

B.

OK – Go to Step 5.

Replace boost pressure/temperature sensor. A.

7.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, go to Step 7.

Replace EGR controller. A.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group for assistance. Wiring harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) Wiring harness - Electrical schematic frame 99 (A.30.A.88-C.20.E.99)

84522361 15/06/2011

A.50.A / 29

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

141-Engine speed sensor fault L223, L225, L230, C227, C232, C238

Control Module : EGR NOTE: The Electronic Service Tool must be used to remove faults from memory. NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical system NOTE: If faults are present in the EST but engine fault lamp is not illuminated, check diagnostic lamp fault line for open circuits. Cause: 1.

Faulty reading from component.

2.

Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.

3.

Wiring or circuits open.

4.

Wiring or circuits shorted.

5.

Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean socket terminals by removing and then reinstalling connector.

Solution: 1.

Use the Electronic Service Tool to check fault status on the Controller Faults page. If Fault 141 is active go to step 2. Clear all fault codes and check for reoccurrence. (1). To check for fault code: Start machine at low idle, increase to full throttle, hold at full throttle longer than 5 seconds.

2.

A.

NOT OK – Fault code 141 is recorded again. Go to Step 2.

B.

OK – Fault is not recorded again. OK for return to service.

Start and run engine at low idle, check reading on EST monitor. (1) Engine speed should be 950 to 1200 RPM.

3.

A.

NOT OK – Go to Step 3.

B.

OK – Return to Step 1 to confirm elimination of fault.If fault is recorded again go to Step 5.

Disconnect the connector at the EGR controller. (1) Take a continuity reading from pin 25 X-EGR to pin 1 at Engine speed sensor connector, a reading of continuity should be obtained. (2) Take a continuity reading from pin 23 X-EGR to pin 2 at Engine speed sensor connector, a reading of continuity should be obtained.

4.

A.

NOT OK – Go to Step 4.

B.

OK – Go to Step 5.

Disconnect connector from EGR harness to engine EGR harness.

84522361 15/06/2011

A.50.A / 30

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

BD08F228-01

1

(1) Take a continuity reading from pin 25 X-EGR to pin 2C at X-FPT (see also: X-FPT) connector, a reading of continuity should be obtained. (2) Take a continuity reading from pin 23 X-EGR to pin 3C at X-FPT (see also: X-FPT) connector, a reading of continuity should be obtained. (3) Take a continuity reading from pin 2C at X-FPT (see also: X-FPT) connector to pin 1 at Engine speed sensor connector, a reading of continuity should be obtained. (4) Take a continuity reading from pin 3C at X-FPT (see also: X-FPT) connector to pin 2 at Engine speed sensor connector, a reading of continuity should be obtained.

5.

A.

NOT OK – Repair or replace harness as needed. Return to Step 1 to confirm elimination of fault.

B.

OK – Go to Step 5.

Replace the engine speed pick up. A.

6.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, go to Step 6.

Replace EGR controller. A.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group for assistance. Wiring harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) Wiring harness - Electrical schematic frame 99 (A.30.A.88-C.20.E.99)

84522361 15/06/2011

A.50.A / 31

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

186-EGR valve position sensor fault L223, L225, L230, C227, C232, C238

Control Module : EGR NOTE: The Electronic Service Tool must be used to remove faults from memory. NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical system NOTE: If faults are present in the EST but engine fault lamp is not illuminated, check diagnostic lamp fault line for open circuits. Cause: 1.

Faulty reading from component.

2.

Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.

3.

Wiring or circuits open.

4.

Wiring or circuits shorted.

5.

Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean socket terminals by removing and then reinstalling connector.

Solution: 1.

Use the Electronic Service Tool to check fault status on the Controller Faults page. If Fault 186 is active go to step 2. (1). Valve movement and feedback can be tested on CONTROLLER TEST page of the EST. (1a) Go to CONTROLLER TEST screen. (1b) Activate START TEST button. (1c) Activate ENABLE button. (1d) Move EGR Valve Control Slider to 100%. (1e) EGR Potentiometer Feedback Signal, Applied Duty Cycle, and EGR Pot Calibration – Higher Stroke should all match within 2%. (A) NOT OK: Values do not match. Go to step 2. (B) OK: Values match. Continue checking for fault reoccurrence. (2) Clear all fault codes and check for reoccurrence. (3) To check for fault code: Start and operate machine for at least 2 seconds.

2.

A.

NOT OK – Fault code 186 is recorded again. Go to Step 2.

B.

OK – Fault is not recorded again. OK for return to service.

Disconnect connector at EGR valve, place the ignition switch in the ON position to check for power and grounding circuits.

84522361 15/06/2011

A.50.A / 32

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

BD08F227-01

1

(1) Turn ignition switch on, check for voltage at pin 2 at EGR valve. (2) Take a continuity reading at pin 4 at EGR valve to ground, a reading of continuity should be obtained. (3) Check for short circuit by measuring continuity from pin 6 to pin 2 and pin 4 on the EGR valve, the circuits should be open. If a short is present go to Step 5. (4) Check for voltage between pin 6 at EGR valve to ground, no voltage should be present.

3.

A.

NOT OK – Go to Step 3.

B.

OK – Go to Step 5.

Disconnect the connectors at the EGR controller and the EGR valve. (1) Take a continuity reading from pin 8 X-EGR to pin 2 at EGR valve, a reading of continuity should be obtained. (2) Take a continuity reading from pin 10 X-EGR to pin 4 at EGR valve, a reading of continuity should be obtained. (3) Take a continuity reading from pin 19 X-EGR to pin 6 at EGR valve, a reading of continuity should be obtained. (4) Take a continuity reading from pin 19 X-EGR to all other EGR controller pins, the circuits should be open.

4.

A.

NOT OK – Go to Step 4.

B.

OK – Go to Step 5.

Disconnect connector from EGR harness to engine EGR harness.

BD08F228-01

2

(1) Take a continuity reading from pin 8 X-EGR to pin 3A at X-FPT connector, a reading of continuity should be obtained. (2) Take a continuity reading from pin 10 X-EGR to pin 5A at X-FPT connector, a reading of continuity should be obtained. 84522361 15/06/2011

A.50.A / 33

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

(3) Take a continuity reading from pin 19 X-EGR to pin 4A at X-FPT connector, a reading of continuity should be obtained. (4) Take a continuity reading from pin 3A at X-FPT connector to pin 2 at EGR valve, a reading of continuity should be obtained. (5) Take a continuity reading from pin 5A at X-FPT connector to pin 4 at EGR valve, a reading of continuity should be obtained. (6) Take a continuity reading from pin 4A at X-FPT connector to pin 6 at EGR valve, a reading of continuity should be obtained. (7) Take a continuity reading from pin 4A X-FPT to all other EGR harness pins, the circuits should be open.

5.

A.

NOT OK – Repair or replace harness as needed. Return to Step 1 to confirm elimination of fault.

B.

OK – Go to Step 5.

Replace EGR valve. A.

6.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, go to Step 6.

Replace EGR controller. A.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group for assistance. Wiring harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) Wiring harness - Electrical schematic frame 99 (A.30.A.88-C.20.E.99)

84522361 15/06/2011

A.50.A / 34

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

189-EGR valve position driver fault L223, L225, L230, C227, C232, C238

Control Module : EGR NOTE: The Electronic Service Tool must be used to remove faults from memory. NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical system NOTE: If faults are present in the EST but engine fault lamp is not illuminated, check diagnostic lamp fault line for open circuits. Cause: 1.

Faulty reading from component.

2.

Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.

3.

Wiring or circuits open.

4.

Wiring or circuits shorted.

5.

Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean socket terminals by removing and then reinstalling connector.

Solution: 1.

Use the Electronic Service Tool to check fault status on the Controller Faults page. If Fault 189 is active go to step 2. (1). Valve movement and feedback can be tested on CONTROLLER TEST page of the EST. (1a) Go to CONTROLLER TEST screen. (1b) Activate START TEST button. (1c) Activate ENABLE button. (1d) Move EGR Valve Control Slider to 100%. (1e) EGR Potentiometer Feedback Signal, Applied Duty Cycle, and EGR Pot Calibration – Higher Stroke should all match within 2%. (2) Clear all fault codes and check for reoccurrence. (3) To check for fault code: (3a) Start engine. (3b) Monitor applied duty cycle with EST. (3c) Start machine at low idle then increase to full throttle. (3d) The applied duty cycle should fluctuate as the controller adjusts the EGR valve. The duty cycle will not change if other faults are preventing valve function.

2.

A.

NOT OK – Fault code 189 is recorded again. Go to Step 2.

B.

OK – Fault is not recorded again. OK for return to service.

Disconnect the connector at the EGR valve.

84522361 15/06/2011

A.50.A / 35

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

BD08F227-01

1

(1) Take a continuity reading at pin 5 at EGR valve to ground, a reading of continuity should be obtained.

3.

A.

NOT OK – Go to Step 3.

B.

OK – Go to Step 5.

Disconnect the connectors at the EGR controller and the EGR valve. (1) Take a continuity reading from pin 1 X-EGR to pin 1 at EGR valve, a reading of continuity should be obtained. (2) Take a continuity reading from pin 3 X-EGR to pin 5 at EGR valve, a reading of continuity should be obtained. (3) Take a continuity reading from pin 1 X-EGR to all other pins in the X-EGR connector, the circuits should be open. (4) Take a continuity reading from pin 3 X-EGR to all other pins in the X-EGR connector, the circuits should be open.

4.

A.

NOT OK – Go to Step 4.

B.

OK – Go to Step 5.

Disconnect connector from EGR harness to engine EGR harness.

BD08F228-01

2

(1) Take a continuity reading from pin 1 X-EGR to pin 1A at X-FPT connector, a reading of continuity should be obtained. (2) Take a continuity reading from pin 3 X-EGR to pin 1B at X-FPT connector, a reading of continuity should be obtained. (3) Take a continuity reading from pin 1A at X-FPT connector to pin 1 at EGR valve, a reading of continuity should be obtained. (4) Take a continuity reading from pin 1B at X-FPT connector to pin 5 at EGR valve, a reading of continuity should be obtained. 84522361 15/06/2011

A.50.A / 36

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

(3) Take a continuity reading from pin 1 X-EGR to all other pins in the X-EGR connector, the circuits should be open. (4) Take a continuity reading from pin 3 X-EGR to all other pins in the X-EGR connector, the circuits should be open.

5.

A.

NOT OK – Repair or replace harness as needed. Return to Step 1 to confirm elimination of fault.

B.

OK – Go to Step 5.

Replace EGR valve. A.

6.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, go to Step 6.

Replace EGR controller. A.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group for assistance. Wiring harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) Wiring harness - Electrical schematic frame 99 (A.30.A.88-C.20.E.99)

84522361 15/06/2011

A.50.A / 37

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1E5-Sensor voltage supply fault L223, L225, L230, C227, C232, C238

Control Module : EGR NOTE: The Electronic Service Tool must be used to remove faults from memory. NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical system NOTE: If faults are present in the EST but engine fault lamp is not illuminated, check diagnostic lamp fault line for open circuits. Cause: 1.

Faulty reading from component.

2.

Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.

3.

Wiring or circuits open.

4.

Wiring or circuits shorted.

5.

Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean socket terminals by removing and then reinstalling connector.

Solution: 1.

Use the Electronic Service Tool to check fault status on the Controller Faults page. If Fault 1E5 is active go to step 2. Clear all fault codes and check for reoccurrence. (1). To check for fault code: Start and operate machine at least 2 seconds.

2.

A.

NOT OK – Fault code 1E5 is recorded again. Go to Step 2.

B.

OK – Fault is not recorded again. OK for return to service.

Disconnect the EGR valve and the boost pressure-temperature sensor.

BD08F227-01

1

EGR valve

84522361 15/06/2011

A.50.A / 38

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

BD08F236-01

2

Boost pressure temperature sensor (1) Turn ignition switch on, check for voltage at pin 2 at EGR valve connector, a reading of approximately 5 V should be obtained. (2) Check for voltage at pin 3 at Boost pressure/temperature sensor connector, a reading of approximately 5 V should be obtained.

3.

A.

NOT OK – Go to Step 3.

B.

OK – Go to Step 5.

(1) Take a continuity reading at the EGR controller from pin 7 on connector X-EGR to pin 3 at Boost pressure/ temperature sensor connector, a reading of continuity should be obtained. (2) Take a continuity reading from the EGR controller, pin 8 of connector X-EGR to pin 2 at EGR valve, a reading of continuity should be obtained. (4) Take a continuity reading from pins 7, 8, 10 and 12 at the EGR controller, X-EGR, to all other pins in the X-EGR connector, all circuits should be open.

4.

A.

NOT OK – Go to Step 4.

B.

OK – Go to Step 5.

Disconnect connector from EGR harness to engine EGR harness.

BD08F228-01

3

(1) Take a continuity reading from pin 7 at the EGR controller X-EGR to pin 2B at engine harness connector, X-FPT (see also connector: X-FPT), a reading of continuity should be obtained. (2) Take a continuity reading from pin 8 EGR controller X-EGR to pin 3A at engine harness connector, EGR valve (see also connector: X-FPT) connector, a reading of continuity should be obtained. (3) Take a continuity reading from pin 2B at engine harness connector, X-FPT (see also connector: X-FPT) connector to pin 3 at Boost pressure/temperature sensor connector , a reading of continuity should be obtained.

84522361 15/06/2011

A.50.A / 39

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

(4) Take a continuity reading from pin 3A at engine harness connector, X-FPT (see also connector: X-FPT) connector to pin 2 at EGR valve connector, a reading of continuity should be obtained. (4) Take a continuity reading from pins 3A, 5A, 6A and 3B at engine harness connector, X-FPT (see also connector: X-FPT) connector to all other engine connector pins, the circuits should be open.

5.

A.

NOT OK – Repair or replace harness as needed. Return to Step 1 to confirm elimination of fault.

B.

OK – Go to Step 5.

Replace EGR controller. A.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group for assistance. Wiring harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) Wiring harness - Electrical schematic frame 99 (A.30.A.88-C.20.E.99)

84522361 15/06/2011

A.50.A / 40

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

2E5-Sensor ground fault L223, L225, L230, C227, C232, C238

Control Module : EGR NOTE: The Electronic Service Tool must be used to remove faults from memory. NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical system NOTE: If faults are present in the EST but engine fault lamp is not illuminated, check diagnostic lamp fault line for open circuits. Cause: 1.

Faulty reading from component.

2.

Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.

3.

Wiring or circuits open.

4.

Wiring or circuits shorted.

5.

Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean socket terminals by removing and then reinstalling connector..

Solution: 1.

Use the Electronic Service Tool to check fault status on the Controller Faults page. If Fault 2E5 is active go to step 2. Clear all fault codes and check for reoccurrence. (1). To check for fault code: Start and operate machine.

2.

A.

NOT OK – Fault code 2E5 is recorded again. Go to Step 2.

B.

OK – Fault is not recorded again. OK for return to service.

Disconnect the EGR valve and the boost pressure-temperature sensor.

BD08F227-01

1

EGR valve

84522361 15/06/2011

A.50.A / 41

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

BD08F236-01

2

Boost pressure temperature sensor (1) Turn ignition switch on, check for voltage at pin 5 at EGR valve connector, voltage should be less than 1.2 V. (2) Check for voltage at pin 4 at EGR valve connector, voltage should be less than 1.2 V. (3) Check for voltage at pin 1 at Boost pressure/temperature sensor sensor connector, voltage should be less than 1.2 V.

3.

A.

NOT OK – Go to Step 3.

B.

OK – Go to Step 5.

Disconnect the connector at the EGR controller.

BD08F234-01

3

(1) Take a continuity reading from pin 12 X-EGR to pin 1 at Boost pressure/temperature sensor sensor connector, a reading of continuity should be obtained. (2) Take a continuity reading from pin 10 X-EGR controller connector to pin 4 at EGR valve connector, a reading of continuity should be obtained. (3) Take a continuity reading from pin 3 X-EGR controller connector to pin 5 at EGR valve connector, a reading of continuity should be obtained. (4) Take a continuity reading from pins 3, 10 and 12 X-EGR controller connector to all other EGR controller pins, all circuits should be open.

4.

A.

NOT OK – Go to Step 4.

B.

OK – Go to Step 5.

Disconnect connector from EGR harness to engine EGR harness.

84522361 15/06/2011

A.50.A / 42

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

BD08F228-01

4

(1) Take a continuity reading from pin 12 X-EGR controller connector to pin 6A at X-FPT connector (also see connector X-FPT), a reading of continuity should be obtained. (2) Take a continuity reading from pin 10 X-EGR controller connector to pin 5A at X-FPT connector (also see connector X-FPT) , a reading of continuity should be obtained. (3) Take a continuity reading from pin 3 X-EGR controller connector to pin 1B at X-FPT connector (also see connector X-FPT), , a reading of continuity should be obtained. (4) Take a continuity reading from pin 6A at X-FPT connector (also see connector X-FPT), to pin 1 at Boost pressure/temperature sensor sensor connector, a reading of continuity should be obtained. (5) Take a continuity reading from pin 5A at X-FPT connector (also see connector X-FPT), to pin 4 at EGR valve, a reading of continuity should be obtained. (6) Take a continuity reading from pin 1B at X-FPT connector (also see connector X-FPT) to pin 5 at EGR valve connector, a reading of continuity should be obtained. (7) Take a continuity reading from pins 3, 10 and 12 X-EGR controller connector to all other EGR controller pins, all circuits should be open. (8) Take a continuity reading from pins 5A, 6A and 1B at X-FPT connector (also see connector X-FPT) to all other engine EGR harness pins, all circuits should be open.

5.

A.

NOT OK – Repair or replace harness as needed. Return to Step 1 to confirm elimination of fault.

B.

OK – Go to Step 5.

Replace EGR controller. A.

Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group for assistance.

84522361 15/06/2011

A.50.A / 43

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1002- Engine Coolant Temperature Sender - Over Temperature >110° C Control Module : IC Context: Diagnostic Trouble Code 1002 has an error priority of Engine-Amber. There are no restrictions with Diagnostic Trouble Code 1002. Cause: Instrument Cluster has sensed that the Engine Coolant Temperature is high. (The fault is only activated when code 3007 is not active, Ignition is On, Start input is low, and temperature is greater than 110 °C (230.0 °F).) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failed ENGINE COOLANT TEMPERATURE SENDER.

3.

Failed INSTRUMENT CLUSTER.

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 1002 - Engine Coolant Temperature Sender - Over Temperature >110° C is active. Verify correct mechanical operation of the Engine Coolant System before troubleshooting this fault electrically. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check for proper resistance in the ENGINE COOLANT TEMPERATURE SENDER. Disconnect connector X-504 (F5C) X-516 (ISM) from the ENGINE COOLANT TEMPERATURE SENDER. Using a multi-meter, check for resistance between ENGINE COOLANT TEMPERATURE SENDER pin 1 and ground. A.

If resistance is more than 134.4 Ω, continue with step 3.

B.

If resistance is less than 134.4 Ω, and the engine coolant is not overheated, the ENGINE COOLANT TEMPERATURE SENDER has failed. Replace the ENGINE COOLANT TEMPERATURE SENDER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 10 (A.30.A.88-C.20.E.10) harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) harness - Electrical schematic frame 13 (A.30.A.88-C.20.E.13)

84522361 15/06/2011

A.50.A / 44

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1004- Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted Control Module : IC Context: Diagnostic Trouble Code 1004 has an error priority of Hydraulic-Amber. There are no restrictions with Diagnostic Trouble Code 1004. Cause: The Instrument Cluster has sensed a clogged hydraulic oil filter. (The fault is only activated when Engine is running and Hydraulic Filter Restriction Switch opens.) Possible failure modes: 1.

Mechanical problem with the Hydraulic oil system.

2.

Failure of Hydraulic Filter Restriction Switch.

3.

Open wire in circuit.

4.

Instrument Cluster Failure.

Solution: 1.

2.

3.

4.

Check if Diagnostic Trouble Code 1201 is active. A.

If Diagnostic Trouble code 1201 is active, it indicates a failed HYDRAULIC FILTER RESTRICTION SWITCH. Follow the resolution procedure for 1201 - Hydraulic Filter Restriction Switch - OC first.When Diagnostic Trouble Code 1201 is no longer active, continue with this procedure.

B.

If Diagnostic Trouble Code 1201 is not active, it indicates a possible mechanical problem with the Hydraulic Oil System. Ensure the hydraulic filter is clean and verify correct mechanical operation of the Hydraulic Oil System before troubleshooting this fault electrically. Continue with step 2.

Use the machine to recreate conditions for error. Use the EST to verify 1004 - Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted is active. A.

If the fault is active, continue with step 3.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for proper resistance in the HYDRAULIC FILTER RESTRICTION SWITCH. Disconnect connector X-OILFLT from the HYDRAULIC FILTER RESTRICTION SWITCH. Using a multi-meter, check for resistance between HYDRAULIC FILTER RESTRICTION SWITCH pin 1 and ground. A.

If resistance is less than 900 Ω, continue with step 4.

B.

If resistance is more than 900 Ω, and the Hydraulic Oil filter is not dirty, the HYDRAULIC FILTER RESTRICTION SWITCH has failed. Replace the HYDRAULIC FILTER RESTRICTION SWITCH.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)

84522361 15/06/2011

A.50.A / 45

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1009- Hydraulic Oil Temperature Sender - Over Temperature >210° F Control Module : IC Context: Fault code 1009 has an error priority of Hydraulic-Amber. There are no restrictions with Fault code 1009. Cause: Instrument Cluster has sensed that the Hydraulic Oil Temperature is high. (The fault is only activated when code 4043 is not active, Ignition is On, Start input is low, and temperature is greater than 110 °C (230.0 °F).) Possible failure modes: 1.

Hydraulic Oil Temperature Sender has failed.

2.

Shorted wire in circuit.

3.

Failure of Instrument Cluster.

Solution: 1.

2.

3.

Verify correct mechanical operation of the Hydraulic Oil System before troubleshooting this fault electrically. Use the machine to recreate conditions for error. Use the EST to verify 1009 - Hydraulic Oil Temperature Sender - Over Temperature >210° F is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check for proper resistance in the HYDRAULIC OIL TEMPERATURE SENDER. Disconnect connector X-OILTMP from the HYDRAULIC OIL TEMPERATURE SENDER. Using a multi-meter, check for resistance across the HYDRAULIC OIL TEMPERATURE SENDER. A.

If resistance is more than 134.4 Ω, continue with step 3.

B.

If resistance is less than 134.4 Ω, and the Hydraulic Oil is not overheated, the HYDRAULIC OIL TEMPERATURE SENDER has failed. Replace the HYDRAULIC OIL TEMPERATURE SENDER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)

84522361 15/06/2011

A.50.A / 46

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1014- Cluster Battery Monitor - Over Voltage > 16.5 volts Control Module : IC Context: Diagnostic Trouble Code 1014 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1014. Cause: Instrument Cluster has sensed that the battery voltage is high. (The fault is only activated when Engine is running and battery voltage is more than 16.5 V.) Possible failure modes: 1.

Failure of Battery or Charging System.

2.

Failure of Instrument Cluster.

Solution: 1.

2.

3.

4.

Check for proper operation of the BATTERY and Charging System. If there is any problem with the charging system, fix the mechanical issues first, before troubleshooting this code electrically. Use the machine to recreate conditions for error. Use the EST to verify 1014 - Cluster Battery Monitor - Over Voltage > 16.5 volts is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for high voltage. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-C23 pin 3 and ground. A.

If voltage is less than 16.5 V, continue with step 3.

B.

If voltage greater than 16.5 V, there is problem with the battery or charging system. Repair the charging system.

Check for high voltage. Using a multi-meter, check for voltage between connector X-C23 pin 23 and ground. A.

If voltage is less than 16.5 V, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

B.

If voltage greater than 16.5 V, there is problem with the battery or charging system. Repair the charging system.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 10 (A.30.A.88-C.20.E.10) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04) 84522361 15/06/2011

A.50.A / 47

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1015-Cluster Battery Monitor - Under Voltage < 11.5 volts Control Module : IC Context: Diagnostic Trouble Code 1015 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1015. Cause: Instrument Cluster has sensed that the battery voltage is low. (The fault is only activated when Engine is Running and battery voltage is less than 11.5 V.) Possible failure modes: 1.

Problem with battery or charging system.

2.

Failure of F-008 (EH) F-007 (Mech) or F-011 in MAIN POWER DISTRIBUTION FUSE BLOCK 1.

3.

Failure of Main Power Relay in MAIN POWER DISTRIBUTION FUSE BLOCK 1.

4.

Shorted wire in circuit.

5.

Open wire in circuit.

6.

Failure of Instrument Cluster.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1015 Cluster Battery Monitor - Under Voltage < 11.5 volts is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 19.

Check for proper voltage. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-C23 pin 3 and ground. A.

If voltage is more than 11.5 V, continue with step 3.

B.

If voltage less than 11.5 V, continue with step 5.

Using a multi-meter, check for voltage between connector X-C23 pin 23 and ground. A.

If voltage is more than 11.5 V, continue with step 4.

B.

If voltage less than 11.5 V, continue with step 5.

Using a multi-meter, check for voltage between connector X-C23 pin 24 and ground. A.

If voltage is more than 11.5 V, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

B.

If voltage less than 11.5 V, continue with step 5.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 3 and 20. A.

If resistance is about 51.8 K Ω, continue with step 6.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 65 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER. 84522361 15/06/2011

A.50.A / 48

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

9.

10.

11.

12.

13.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 23 and 20. A.

If resistance is about 9.95 K Ω, continue with step 7.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 16 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 24 and 20. A.

If resistance is about 9.95 K Ω, continue with step 8.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 16 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 21 and 20. A.

If resistance is about 244 K Ω, continue with step 9.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 300 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Check for blown fuse. Remove fuse F-011 from MAIN POWER DISTRIBUTION FUSE BLOCK 1. Using a multi-meter, check for resistance across the fuse. A.

If resistance is 0 Ω, re-insert fuse and continue with step 10.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for blown fuse. Remove fuse F-008 (EH) F-007 (Mech) from MAIN POWER DISTRIBUTION FUSE BLOCK 1. Using a multi-meter, check for resistance across the fuse. A.

If resistance is 0 Ω, re-insert fuse and continue with step 11.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for proper operation of the MAIN POWER RELAY. If a spare relay is not available, disconnect the ACCESSORY RELAY from MAIN POWER DISTRIBUTION FUSE BLOCK 1. Connect the substitute relay to the MAIN POWER RELAY socket on MAIN POWER DISTRIBUTION FUSE BLOCK 1. Reconnect all connectors and turn on ignition. A.

If Trouble Code 1015 is no longer active, the MAIN POWER RELAY has failed. Replace the MAIN POWER RELAY.

B.

If Trouble Code 1015 is still active, re-insert relay and continue with step 12.

Check for open circuit. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Disconnect fuse F-011 from the MAIN POWER DISTRIBUTION FUSE BLOCK 1. Using a multi-meter, check continuity between connector X-C23 pin 3 and MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin D2. A.

If there is continuity, continue with step 15.

B.

If there is no continuity, there is an open wire condition on wire 161/310/313 (Red) between connector X-C23 pin 3 and MAIN POWER DISTRIBUTION FUSE BLOCK 1. Continue with step 13.

Locate the open circuit. Disconnect connector X-ECC1B (EH) X-CC1B (Mech) from connector X-ECC1A (EH) X-CC1A (Mech). Using a multi-meter, check continuity between connector X-ECC1B (EH) X-CC1B (Mech) pin 12 and MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin D2.

84522361 15/06/2011

A.50.A / 49

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

14.

15.

16.

17.

18.

19.

A.

If there is no continuity, there is an open wire condition on wire 310/161 (Red) between connector X-ECC1B (EH) X-CC1B (Mech) pin 12 and MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin D2. Repair or replace the wire.

B.

If there is continuity, continue with step 14.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC1A (EH) X-CC1A (Mech) pin 12 and connector X-C23 pin 3. A.

If there is no continuity, there is an open wire condition on wire 310/313 (Red) between connector X-ECC1A (EH) X-CC1A (Mech) pin 12 and connector X-C23 pin 3. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC1B (EH) X-CC1B (Mech) and X-ECC1A (EH) X-CC1A (Mech) are not making a good connection at pin 12. Repair the connector.

Check for open circuit. Disconnect fuse F-008 (EH) F-007 (Mech) from the MAIN POWER DISTRIBUTION FUSE BLOCK 1. Using a multi-meter, check continuity between connector X-C23 pin 23 and MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin D4. A.

If there is continuity, continue with step 18.

B.

If there is no continuity, there is an open wire condition on wire 301/309/300 (Orange) between connector X-C23 pin 23 and MAIN POWER DISTRIBUTION FUSE BLOCK 1. Continue with step 13.

Locate the open circuit. Disconnect connector X-ECC2B (EH) X-CC2B (Mech) from connector X-ECC2A (EH) X-CC2A (Mech). Using a multi-meter, check continuity between connector X-ECC2B (EH) X-CC2B (Mech) pin 4 and MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin D4. A.

If there is no continuity, there is an open wire condition on wire 300/309 (Orange) between connector X-ECC2B (EH) X-CC2B (Mech) pin 4 and MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin D4. Repair or replace the wire.

B.

If there is continuity, continue with step 17.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC2A (EH) X-CC2A (Mech) pin 4 and connector X-C23 pin 23. A.

If there is no continuity, there is an open wire condition on wire 301/309 (Orange) between connector X-ECC2A (EH) X-CC2A (Mech) pin 4 and connector X-C23 pin 3. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC2B (EH) X-CC2B (Mech) and X-ECC2A (EH) X-CC2A (Mech) are not making a good connection at pin 4. Repair the connector.

Check for open circuit. Disconnect connector X-ECC2B (EH) X-CC2B (Mech) from connector X-ECC2A (EH) X-CC2A (Mech). Using a multi-meter, check continuity between connector X-ECC2A (EH) X-CC2A (Mech) pin 4 and connector X-C23 pin 24. A.

If there is no continuity, there is an open wire condition on wire 302 (Orange) between SPLICE 010 and connector X-C23 pin 24. Repair or replace the wire.

B.

If there is continuity, continue with step 19.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 10 (A.30.A.88-C.20.E.10) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) 84522361 15/06/2011

A.50.A / 50

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)

84522361 15/06/2011

A.50.A / 51

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1041- RPM Monitoring - Over Speed Control Module : IC Context: Diagnostic Trouble Code 1041 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 1041. Cause: Instrument Cluster has sensed high Engine RPM. (The fault is only activated when Engine is Running , code 9406 is not active and Engine RPM is greater than 2800 RPM (F5C) 3230 RPM (ISM).) Possible failure modes: 1.

Failure of Alternator.

2.

Failure of Instrument Cluster.

3.

Failure of UCM.

Solution: 1.

2.

Verify correct mechanical operation of the Engine before troubleshooting this fault electrically. Use the machine to recreate conditions for error. Use the EST to verify 1041 - RPM Monitoring - Over Speed is active. A.

If the fault is active, Follow procedure for 1203 - RPM Monitoring - Open Circuit / STG / STP.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 2.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 52

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1045- Fuel Level Sensor - OC Control Module : IC Context: Fault code 1045 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Fault code 1045. Cause: Instrument Cluster has determined that the Fuel Level Sensor resistance has failed high. (The fault is only activated when Ignition is on and Fuel Level Sensor resistance indicates high.) Possible failure modes: 1.

Fuel Level Sensor has failed.

2.

Open wire in circuit.

3.

Instrument Cluster has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1045 - Fuel Level Sensor - OC is present. A.

If the fault is present, continue with step 2.

B.

If the fault is not present, the fault may be intermittent and not currently active, continue with step 8.

Disconnect connector X-14 from the FUEL LEVEL SENSOR. Check for an open condition across the sensor by using a multi-meter to check resistance between Fuel Level Sensor pins A and B. A.

If the resistance is between 1 Ω and 95 Ω for small frame skid steers, or between 26 Ω and 255 Ω for medium and large frame skid steers, continue with step 3.

B.

If the resistance is greater than 5000 Ω, the sensor is open. Replace the sensor.

Disconnect connector X-C23 from the Instrument Cluster. Check for an open wire condition by using a multimeter to check continuity between connector X-14 pin B and connector X-C23 pin 1. A.

If there is continuity, continue with step 6.

B.

If there is no continuity, there is an open on wire 234 (Red/Yellow) between connector X-14 pin B and connector X-C23 pin 1. Continue with step 4 to isolate fault.

Disconnect connector X-ECC1A (EH) X-CC1A (Mech) from connector X-ECC1B (EH) X-CC1B (Mech) . Check for an open wire condition by using a multi-meter to check continuity between connector X-14 pin B and connector X-ECC1B (EH) X-CC1B (Mech) pin 8. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 234 (Red) between connector X-14 pin B and connector X-ECC1B (EH) X-CC1B (Mech) pin 8. Repair or replace the faulty wire.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC1A (EH) X-CC1A (Mech) pin 8 and connector X-C23 pin 1. A.

If there is no continuity, there is an open wire condition on wire 234 (Yellow) between connector X-ECC1A (EH) X-CC1A (Mech) pin 8 and connector X-C23 pin 1. Repair or replace the faulty wire.

B.

If there is continuity, connectors X-ECC1A (EH) X-CC1A (Mech) and X-ECC1B (EH) X-CC1B (Mech) are not making a good connection at pin 8. Repair the connector. 84522361 15/06/2011

A.50.A / 53

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

Check for continuity in the ground circuit. Disconnect connector X-14 from the FUEL LEVEL SENSOR. Use a multi-meter to check for continuity between connector X-14 pin A and ground. A.

If there is no continuity, there is an open in the ground circuit. Use frames 1 and 2 to locate and isolate the faulty wire. Repair or replace the wire.

B.

If there is continuity, continue with step 7.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 1 and 20. A.

If resistance is about 3.69 M Ω, continue with step 8.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 4.5 M Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 54

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1201- Hydraulic Filter Restriction Switch - OC Control Module : IC Context: Diagnostic Trouble Code 1201 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 1201. Cause: Instrument Cluster has sensed that the Hydraulic Filter indicates clogged. (The fault is only activated when Ignition is On and Start input is low and the Hydraulic Filter Restriction switch is open.) Possible failure modes: 1.

Failure of Hydraulic Filter Restriction Switch.

2.

Open wire in circuit.

3.

Failure of Instrument Cluster.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1201 - Hydraulic Filter Restriction Switch - OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for proper resistance in the HYDRAULIC FILTER RESTRICTION SWITCH. Disconnect connector X-OILFLT from the HYDRAULIC FILTER RESTRICTION SWITCH. Using a multi-meter, check for resistance between HYDRAULIC FILTER RESTRICTION SWITCH pin 1 and ground. A.

If resistance is more than 900 Ω, the HYDRAULIC FILTER RESTRICTION SWITCH has failed. Replace the HYDRAULIC FILTER RESTRICTION SWITCH.

B.

If resistance is less than 900 Ω, continue with step 3.

Check for open circuit. Disconnect connector X-OILFLT from the HYDRAULIC FILTER RESTRICTION SWITCH. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-OILFLT pin 1 and connector X-C23 pin 15. A.

If there is continuity, continue with step 6.

B.

If there is no continuity, there is an open wire condition on wire 261 (Yellow) between connector X-OILFLT pin 1 and connector X-C23 pin 15. Continue with step 4.

Locate the open circuit. Disconnect connector X-ECC2A (EH) X-CC2A (Mech) from connector X-ECC2B (EH) X-CC2B (Mech). Using a multi-meter, check continuity between connector X-ECC2A (EH) X-CC2A (Mech) pin 6 and connector X-C23 pin 15. A.

If there is no continuity, there is an open wire condition on wire 261 (Yellow) between connector X-ECC2A (EH) X-CC2A (Mech) pin 6 and connector X-C23 pin 15. Repair or replace the wire.

B.

If there is continuity, continue with step 5.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC2B (EH) X-CC2B (Mech) pin 6 and connector X-OILFLT pin 1. A.

If there is no continuity, there is an open wire condition on wire 261 (Yellow) between connector X-ECC2B (EH) X-CC2B (Mech) pin 6 and connector X-OILFLT pin 1. Repair or replace the wire.

84522361 15/06/2011

A.50.A / 55

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

If there is continuity, connectors X-ECC2A (EH) X-CC2A (Mech) and X-ECC2B (EH) X-CC2B (Mech) are not making a good connection at pin 6. Repair the connector.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 15 and 20. A.

If resistance is about 10.55 K Ω, continue with step 7.

B.

If resistance is greater than 15 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)

84522361 15/06/2011

A.50.A / 56

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1202- RPM Monitoring - Over Speed (Max) Control Module : IC Context: Diagnostic Trouble Code 1202 has an error priority of Red. The vehicle is disabled with Diagnostic Trouble Code 1202. Cause: Instrument Cluster has sensed very high Engine RPM. (The fault is only activated when Engine is Running , code 9406 is not active and Engine RPM is greater than 2900 RPM (F5C) 3330 RPM (ISM).) Possible failure modes: 1.

Failure of Alternator.

2.

Failure of Instrument Cluster.

3.

Failure of UCM.

Solution: 1.

2.

3.

Verify correct mechanical operation of the Engine before troubleshooting this fault electrically. Use the machine to recreate conditions for error. Use the EST to verify 1202 - RPM Monitoring - Over Speed (Max) is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check if Diagnostic Trouble Code 1041 or 1203 is active. A.

If Diagnostic Trouble Code 1041 or 1203 is not active, continue with step 3.

B.

If Diagnostic Trouble Code 1041 or 1203 is active, follow procedure for 1203 - RPM Monitoring - Open Circuit / STG / STP.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 57

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1203- RPM Monitoring - Open Circuit / STG / STP Control Module : IC NOTE: For EH machines, follow steps 1, and 13-22. For Mechanical machines, follow steps 1-12, and 22. Context: Diagnostic Trouble Code 1203 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1203. Cause: Instrument Cluster has sensed that the Alternator Tach signal has failed. (The fault is only activated when Engine is running , code 9406 is not active and Instrument Cluster senses low RPM.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Open wire in circuit.

3.

Failure of Instrument Cluster.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1203 - RPM Monitoring - Open Circuit / STG / STP is active. A.

If the fault is active, continue with step 2 for Mechanical machines, or 13 for EH machines.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 22.

Check for open circuit. Disconnect connector X-5 from the ALTERNATOR. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-5 pin 3 and connector X-C23 pin 19. A.

If there is continuity, continue with step 6.

B.

If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-5 pin 3 and connector X-C23 pin 19. Continue with step 3.

Locate the open circuit. Disconnect connector X-CC1A from connector X-CC1B. Disconnect connector X-52B from connector X-52A. Using a multi-meter, check continuity between connector X-CC1A pin 6 and connector X-C23 pin 19. A.

If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-CC1A pin 6 and connector X-C23 pin 19. Repair or replace the wire.

B.

If there is continuity, continue with step 4.

Locate the open circuit. Using a multi-meter, check continuity between connector X-CC1B pin 6 and connector X-52B pin 4. A.

If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-CC1B pin 6 and connector X-52B pin 4. Repair or replace the wire.

B.

If there is continuity, continue with step 5.

Locate the open circuit. Using a multi-meter, check continuity between connector X-5 pin 3 and X-52A pin 4. A.

If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-52A pin 4 and connector X-5 pin 3. Repair or replace the wire.

84522361 15/06/2011

A.50.A / 58

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

10.

11.

12.

13.

If there is continuity, connectors X-CC1A and X-CC1B are not making a good connection at pin 6, or connectors X-52A and X-52B are not making a good connection at pin 4. Repair the connector.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-C23 pin 19 and ground. A.

If there is no continuity, continue with step 9.

B.

If there is continuity, there is a short to ground condition on wire 124 (Yellow) between connector X-5 pin 3 and connector X-C23 pin 19. Continue with step 7.

Locate the short to ground. Disconnect connector X-CC1A from connector X-CC1B. Disconnect connector X-52A from connector X-52B. Using a multi-meter, check for continuity between connector X-C23 pin 19 and ground. A.

If there is no continuity, continue with step 8.

B.

If there is continuity, there is a short to ground condition on wire 124 (Yellow) between connector X-CC1A pin 6 and connector X-C23 pin 19. Repair or replace the shorted wire.

Locate the short to ground. Using a multi-meter, check for continuity between connector X-CC1B pin 6 and ground. A.

If there is no continuity, there is a short to ground on wire 124 (Yellow) between connector X-5 pin 3 and X-52A pin 4. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 124 (Yellow) between connector X-CC1B pin 6 and connector X-52B pin 4. Repair or replace the shorted wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-C23 pin 19 and ground. A.

If there is no voltage, continue with step 12.

B.

If there is voltage, there is a short to high source on wire 124 (Yellow) between connector X-5 pin 3 and connector X-C23 pin 19. Continue with step 10.

Locate the short to high. Disconnect connector X-CC1A from connector X-CC1B. Disconnect connector X-52A from connector X-52B. Using a multi-meter, check for voltage between connector X-5 pin 3 and ground. A.

If there is no voltage, continue with step 11.

B.

If there is voltage, there is a short to high source on wire 124 (Yellow) between connector X-5 pin 3 and connector X-CC1B pin 6. Repair or replace the wire.

Locate the short to high. Using a multi-meter, check for voltage between connector X-52B pin 4 and ground. A.

If there is no voltage, there is a short to high source on wire 124 (Yellow) between connector X-CC1A pin 6 and connector X-C23 pin 19. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 124 (Yellow) between connector X-52B pin 4 and connector X-CC1B pin 6. Repair or replace the wire.

Check for proper resistance of the INSTRUMENT CLUSTER. Disconnect connector X-C23 to the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 19 and 20. A.

If resistance is about 1.1 M Ω, continue with step 22.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 1.5 M Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Check for open circuit. Disconnect connector X-5 from the ALTERNATOR. Disconnect connector X-CN1A from the UCM. Using a multi-meter, check continuity between connector X-5 pin 3 and connector X-CN1A pin 16. A.

If there is continuity, continue with step 16.

84522361 15/06/2011

A.50.A / 59

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 14.

15.

16.

17.

18.

19.

20.

21.

If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-5 pin 3 and connector X-CN1A pin 16. Continue with step 14.

Locate the open circuit. Disconnect connector X-52B from connector X-52A. Using a multi-meter, check continuity between connector X-52B pin 4 and connector X-CN1A pin 16. A.

If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-CC1A pin 6 and connector X-CN1A pin 16. Repair or replace the wire.

B.

If there is continuity, continue with step 15.

Locate the open circuit. Using a multi-meter, check continuity between connector X-5 pin 3 and X-52A pin 4. A.

If there is no continuity, there is an open wire condition on wire 124 (Yellow) between connector X-52A pin 4 and connector X-5 pin 3. Repair or replace the wire.

B.

If there is continuity, connectors X-52A and X-52B are not making a good connection at pin 4. Repair the connector.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-CN1A pin 16 and ground. A.

If there is no continuity, continue with step 18.

B.

If there is continuity, there is a short to ground condition on wire 124 (Yellow) between connector X-5 pin 3 and connector X-CN1A pin 16. Continue with step 17.

Locate the short to ground. Disconnect connector X-52A from connector X-52B. Using a multi-meter, check for continuity between connector X-CN1A pin 16 and ground. A.

If there is no continuity, there is a short to ground on wire 124 (Yellow) between connector X-5 pin 3 and X-52A pin 4. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 124 (Yellow) between connector X-52B pin 4 and connector X-CN1A pin 16. Repair or replace the shorted wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-CN1A pin 16 and ground. A.

If there is no voltage, continue with step 20.

B.

If there is voltage, there is a short to high source on wire 124 (Yellow) between connector X-5 pin 3 and connector X-CN1A pin 16. Continue with step 19.

Locate the short to high. Disconnect connector X-52A from connector X-52B. Using a multi-meter, check for voltage between connector X-5 pin 3 and ground. A.

If there is no voltage, there is a short to high source on wire 124 (Yellow) between connector X-CN1A pin 16 and connector X-52B pin 4. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 124 (Yellow) between connector X-5 pin 3 and connector X-52A pin 4. Repair or replace the wire.

Check for proper operation of the UCM. Reconnect connector X-CN1A to the UCM. Using a multi-meter, check for voltage between connector X-52B pin 4 and ground. A.

If there is voltage, the UCM has failed. Replace the UCM.

B.

If voltage is 0 V, continue with step 21.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1A-16 and CN1A-1. A.

If resistance is normal, continue with step 22.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM. 84522361 15/06/2011

A.50.A / 60

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

22.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 10 (A.30.A.88-C.20.E.10) harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) harness - Electrical schematic frame 13 (A.30.A.88-C.20.E.13)

84522361 15/06/2011

A.50.A / 61

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1204- Start Sequence - Key Switch State - Engine Running Plausability Fault Control Module : IC Context: Diagnostic Trouble Code 1204 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 1204. Cause: Instrument Cluster does not think that the engine is running when there are indications that the engine is running. (The fault is only activated when Engine is Running.) Possible failure modes: 1.

Open wire in circuit.

2.

Failure of the Instrument Cluster.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1204 - Start Sequence - Key Switch State - Engine Running Plausability Fault is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check if any other Diagnostic Trouble Codes are active. A.

If any other Diagnostic Trouble Codes are active, follow the resolution procedure for those codes first. When all other Diagnostic Trouble Codes are no longer active, continue with this procedure.

B.

If no other Diagnostic Trouble Codes are active, continue with step 3.

Check for proper resistance of the INSTRUMENT CLUSTER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 11 and 20. A.

If resistance is about 603 Ω, continue with step 4.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 750 Ω, the INSTRUMENT CLUSTER has opened internally. INSTRUMENT CLUSTER.

Replace the

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 9 and 20. A.

If resistance is about 244 K Ω, continue with step 5.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 300 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 18 and 20. A.

If resistance is about 10.55 K Ω, continue with step 6.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER. 84522361 15/06/2011

A.50.A / 62

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

C. 6.

7.

If resistance is greater than 13 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

For Mechanical machines, check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 19 and 20. A.

If resistance is about 1.1 M Ω, continue with step 7.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 1.4 M Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 63

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1205- Hydraulic Enable (EH Machines) - Hydraulic Enable Output STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : IC Context: Fault code 1205 has an error priority of Amber. There are no restrictions with Fault code 1205. Cause: The Instrument Cluster has determined that the Hydraulic Enable output from the Instrument Cluster does not match the request from the Instrument Cluster. (The fault is only activated when Ignition is on and Hydraulic Enable Commanded State is Low and Hydraulic Enable Solenoid is energized.) Possible failure modes: 1.

Shorted or open wire in circuit.

2.

Failure of UCM.

3.

Instrument Cluster has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1205 - Hydraulic Enable (EH Machines) - Hydraulic Enable Output - STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 11.

Check for short to high. Disconnect connector X-CN3A from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-CN3A pin 23, or connector X-C23 pin 14 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 303 (White) between connector X-CN3A pin 23 and connector X-C23 pin 14. Continue with step 3.

Locate the short to high. Disconnect connector X-ECC2A from connector X-ECC2B. Using a multi-meter, check for voltage between connector X-CN3A pin 23, or connector X-ECC2B pin 5 and ground. A.

If there is no voltage, there is a short to high source on wire 303 (White) between connector X-ECC2A pin 5 and connector X-C23 pin 14. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 303 (White) between connector X-CN3A pin 23 and connector X-ECC2B pin 5. Repair or replace the wire.

Check for open circuit. Disconnect connector X-CN3A from the UCM. Disconnect connector X-C23 from the UCM. Using a multi-meter, check continuity between connector X-CN3A pin 23 and connector X-C23 pin 14. A.

If there is continuity, continue with step 7.

B.

If there is no continuity, there is an open wire condition on wire 303 (White) between connector X-CN3A pin 23 and connector X-C23 pin 14. Continue with step 5.

Locate the open circuit. Disconnect connector X-ECC2A from connector X-ECC2B. Using a multi-meter, check continuity between connector X-ECC2A pin 5 and connector X-C23 pin 14.

84522361 15/06/2011

A.50.A / 64

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

9.

10.

11.

A.

If there is no continuity, there is an open wire condition on wire 303 (White) between connector X-ECC2A pin 5 and connector X-C23 pin 14. Repair or replace the wire.

B.

If there is continuity, continue with step 6

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC2B pin 5 and connector X-CN3A pin 23. A.

If there is no continuity, there is an open wire condition on wire 303 (White) between connector X-ECC2B pin 5 and connector X-CN3A pin 23. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC2A and X-ECC2B are not making a good connection at pin 5. Repair the connector.

Check for a short to ground. Disconnect connector X-CN3A from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for continuity between connector X-CN3A pin 23, or connector X-C23 pin 14 and ground. A.

If there is no continuity, continue with step 9.

B.

If there is continuity, there is a short to ground condition on wire 303 (White) between connector X-CN3A pin 23 and connector X-C23 pin 14. Continue with step 8.

Locate the short to ground. Disconnect connector X-ECC2A from connector X-ECC2B. Using a multi-meter, check for continuity between connector X-ECC2A pin 5, or connector X-C23 pin 14 and ground. A.

If there is no continuity, there is a short to ground on wire 303 (White) between connector X-CN3A pin 23 and X-ECC2B pin 5. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 303 (White) between connector X-ECC2A pin 5 and connector X-C23 pin 14. Repair or replace the shorted wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3A-23 and CN1A-1. A.

If resistance is normal, continue with step 10.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 14 and 20.. A.

If resistance is about 250 K Ω, continue with step 11.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the UCM.

C.

If resistance is greater than 300 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 65

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1208- Seat Switch - Plausibility Fault L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : IC Context: Diagnostic Trouble Code 1208 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1208. Cause: The Instrument Cluster and UCM do not agree on the presence of an operator. (The fault is only activated when Ignition is On.) Possible failure modes: 1.

Open wire in circuit.

2.

Failure of EH Seat Sw UCM Diode.

3.

Failure of Instrument Cluster.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 1208 - Seat Switch - Plausibility Fault is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 9.

Check for proper operation of the Diode V-005, the EH Seat Sw UCM Diode. Disconnect connector X-98 from the EH Seat Sw UCM Diode. Using a multi-meter on the diode setting, measure the diode from pin A to pin B. The reading should be near the range of 0.3 V to 0.7 V. Reverse the leads. The reading should be infinite. A.

If your reading is the same in both directions, the diode is shorted. Replace diode.

B.

If reading is near 3 V or infinite in both directions, the diode is open. Replace diode.

C.

If the readings are correct, continue with step 3.

Check for proper resistance of the INSTRUMENT CLUSTER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 12 and 20. A.

If resistance is about 603 Ω, continue with step 4.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 750 Ω, the INSTRUMENT CLUSTER has opened internally. INSTRUMENT CLUSTER.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1A-14 and CN1A-1. A.

If resistance is normal, continue with step 5.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM. 84522361 15/06/2011

A.50.A / 66

Replace the

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5.

6.

7.

8.

9.

Check for open circuit. Using a multi-meter, check continuity between connector X-C23 pin 12 and connector X-98 pin A. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open wire condition on wire 328/329/332 (Yellow) between connector X-C23 pin 12 and connector X-98 pin A. Continue with step 6.

Locate the open circuit. Disconnect connector X-ECC2B from connector X-ECC2A. Using a multi-meter, check continuity between connector X-ECC2B pin 3 and connector X-98 pin A. A.

If there is no continuity, there is an open wire condition on wire 332 (Yellow) between connector X-ECC2B pin 3 and connector X-98 pin A. Repair or replace the wire.

B.

If there is continuity, continue with step 7.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC2A pin 3 and connector X-C23 pin 12. A.

If there is no continuity, there is an open wire condition on wire 328/329 (Yellow) between connector X-ECC2A pin 3 and connector X-C23 pin 12. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC2B and X-ECC2A are not making a good connection at pin 3. Repair the connector.

Check for an open circuit. Using a multi-meter, check continuity between connector X-98 pin B and connector X-CN1A pin 14. A.

If there is no continuity, there is an open wire condition on wire 330/525 (Yellow) between connector X-98 pin Band connector X-CN1A pin 14. Repair or replace the wire.

B.

If there is continuity, continue with step 9.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM or Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the UCM or Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) Wiring harness - Electrical schematic frame 20 (A.30.A.88-C.20.E.20)

84522361 15/06/2011

A.50.A / 67

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

3000- Engine Malfunction - ECU Fault - General/Undefined/Air Filter Restriction Control Module : IC Context: Diagnostic Trouble Code 3000 has an error priority of Engine-Amber. There are no restrictions with Diagnostic Trouble Code 3000. Cause: Instrument Cluster has sensed that the Air Filter Restriction Switch is closed or, for F5C engines, the EGR unit has generated a fault. (The fault is only activated when Ignition is On and Start input is low.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failed AIR FILTER RESTRICTION SWITCH.

3.

Failed INSTRUMENT CLUSTER.

4.

For F5C engines, failed EGR.

Solution: 1.

2.

3.

4.

5.

Verify correct mechanical operation of the Air Intake System before troubleshooting this fault electrically. Use the machine to recreate conditions for error. Use the EST to verify 3000 - Engine Malfunction - ECU Fault General/Undefined/Air Filter Restriction is active. For F5C engines, use EST to check for, diagnose, and resolve any EGR related error codes. The following steps only troubleshoot a failed AIR FILTER RESTRICTION SWITCH circuit. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for proper resistance in the AIR FILTER RESTRICTION SWITCH. Disconnect connector X-508 from the AIR FILTER RESTRICTION SWITCH. Using a multi-meter, check for resistance between AIR FILTER RESTRICTION SWITCH pins 1 and 2. A.

If resistance is infinite, continue with step 3.

B.

If resistance is 0 Ω, the AIR FILTER RESTRICTION SWITCH is shorted. Replace the AIR FILTER RESTRICTION SWITCH.

Check for a short to ground. Disconnect connector X-508 from the AIR FILTER RESTRICTION SWITCH. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for continuity between connector X-508 pin 1, or connector X-C23 pin 16 and ground. A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 267 (Yellow) between connector X-508 pin 1 and connector X-C23 pin 16. Continue with step 4.

Locate the short to ground. Disconnect connector X-ECC2A (EH) X-CC2A (Mech) from connector X-ECC2B (EH) X-CC2B (Mech). Disconnect connector X-52A from connector X-52B. Using a multi-meter, check for continuity between connector X-ECC2A (EH) X-CC2A (Mech) pin 7 and ground. A.

If there is no continuity, Continue with step 5.

B.

If there is continuity, there is a short to ground condition on wire 267 (Yellow) between connector X-ECC2A (EH) X-CC2A (Mech) pin 7 and connector X-C23 pin 16. Repair or replace the shorted wire.

Locate the short to ground. Using a multi-meter, check for continuity between connector X-52A pin 1 and ground.

84522361 15/06/2011

A.50.A / 68

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

A.

If there is no continuity, there is a short to ground on wire 267 (Yellow) between connector X-52B pin 1 and X-ECC2B (EH) X-CC2B (Mech) pin 7. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 267 (Yellow) between connector X-52A pin 1 and connector X-508 pin 1. Or between SP-001 and X-EGR pin 17 (F5C). Repair or replace the shorted wire.

Check for proper operation of the INSTRUMENT CLUSTER. Reconnect connector X-C23 to the INSTRUMENT CLUSTER. Start the engine. A.

If Code 3000 is no longer active, continue with step 7.

B.

If Code 3000 is still active, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 10 (A.30.A.88-C.20.E.10) harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) harness - Electrical schematic frame 13 (A.30.A.88-C.20.E.13)

84522361 15/06/2011

A.50.A / 69

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

3007- Engine Coolant Temperature Sender - STG Control Module : IC Context: Diagnostic Trouble Code 3007 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 3007. Cause: Instrument Cluster has sensed that the Engine Coolant Temperature Sender has failed. (The fault is only activated when Ignition is On, Start input is low, and Engine Coolant Temperature Sender resistance is less than 25 Ω.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Engine Coolant Temperature Sender.

3.

Failure of Instrument Cluster.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 3007 - Engine Coolant Temperature Sender - STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for proper resistance in the ENGINE COOLANT TEMPERATURE SENDER. Disconnect connector X-504 (F5C) X-516 (ISM) from the ENGINE COOLANT TEMPERATURE SENDER. Using a multi-meter, check for resistance between ENGINE COOLANT TEMPERATURE SENDER pin 1 and ground. A.

If resistance is between 50 Ω and 9850 Ω, continue with step 3.

B.

If resistance is 0 Ω, the ENGINE COOLANT TEMPERATURE SENDER is shorted. Replace the ENGINE COOLANT TEMPERATURE SENDER.

Check for a short to ground. Disconnect connector X-504 (F5C) X-516 (ISM) from the ENGINE COOLANT TEMPERATURE SENDER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for continuity between connector X-504 (F5C) X-516 (ISM) pin 1, or connector X-C23 pin 25 and ground. A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 257 (Yellow) between connector X-504 (F5C) X-516 (ISM) pin 1 and connector X-C23 pin 25. Continue with step 4.

Locate the short to ground. Disconnect connector X-ECC2A (EH) X-CC2A (Mech) from connector X-ECC2B (EH) X-CC2B (Mech). Disconnect connector X-52A from connector X-52B. Using a multi-meter, check for continuity between connector X-ECC2A (EH) X-CC2A (Mech) pin 13 and ground. A.

If there is no continuity, Continue with step 5.

B.

If there is continuity, there is a short to ground condition on wire 257 (Yellow) between connector X-ECC2A (EH) X-CC2A (Mech) pin 13 and connector X-C23 pin 25. Repair or replace the shorted wire.

Locate the short to ground. Using a multi-meter, check for continuity between connector X-52A pin 3 and ground. A.

If there is no continuity, there is a short to ground on wire 257 (Yellow) between connector X-52B pin 3 and X-ECC2B (EH) X-CC2B (Mech) pin 13. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 257 (Yellow) between connector X-52A pin 3 and connector X-504 (F5C) X-516 (ISM) pin 1. Repair or replace the shorted wire. 84522361 15/06/2011

A.50.A / 70

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

Check for proper resistance of the INSTRUMENT CLUSTER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 25 and 20. A.

If resistance is about 3.7 M Ω, continue with step 7.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 10 (A.30.A.88-C.20.E.10) harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) harness - Electrical schematic frame 13 (A.30.A.88-C.20.E.13)

84522361 15/06/2011

A.50.A / 71

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

3008- Engine Coolant Temperature Sender - OC Control Module : IC Context: Diagnostic Trouble Code 3008 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 3008. Cause: Instrument Cluster has sensed that the Engine Coolant Temperature Sender has failed. (The fault is only activated when Ignition is On and Start input is low and Engine Coolant Temperature Sender Resistance is greater than 30 K Ω.) Possible failure modes: 1.

Failure of Engine Coolant Temperature Sender.

2.

Open wire in circuit.

3.

Failure of Instrument Cluster.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 3008 - Engine Coolant Temperature Sender - OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for proper resistance in the ENGINE COOLANT TEMPERATURE SENDER. Disconnect connector X-504 (F5C) X-516 (ISM) from the ENGINE COOLANT TEMPERATURE SENDER. Using a multi-meter, check for resistance between ENGINE COOLANT TEMPERATURE SENDER pin 1 and ground. A.

If resistance is 50 Ω to 9800 Ω, continue with step 3.

B.

If resistance greater than 30 K Ω, the ENGINE COOLANT TEMPERATURE SENDER has developed an open. Replace the ENGINE COOLANT TEMPERATURE SENDER.

Check for open circuit. Disconnect connector X-504 (F5C) X-516 (ISM) from the ENGINE COOLANT TEMPERATURE SENDER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-504 (F5C) X-516 (ISM) pin 1 and connector X-C23 pin 25. A.

If there is continuity, continue with step 7.

B.

If there is no continuity, there is an open wire condition on wire 257 (Yellow) between connector X-504 (F5C) X-516 (ISM) pin 1 and connector X-C23 pin 25. Continue with step 4.

Locate the open circuit. Disconnect connector X-ECC2A (EH) X-CC2A (Mech) from connector X-ECC2B (EH) X-CC2B (Mech). Disconnect connector X-52A from connector X-52B . Using a multi-meter, check continuity between connector X-ECC2A (EH) X-CC2A (Mech) pin 13 and connector X-C23 pin 25. A.

If there is no continuity, there is an open wire condition on wire 257 (Yellow) between connector X-ECC2A (EH) X-CC2A (Mech) pin 13 and connector X-C23 pin 25. Repair or replace the wire.

B.

If there is continuity, continue with step 5

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC2B (EH) X-CC2B (Mech) pin 13 and connector X-52B pin 3. A.

If there is no continuity, there is an open wire condition on wire 257 (Yellow) between connector X-ECC2B (EH) X-CC2B (Mech) pin 13 and connector X-52B pin 3. Repair or replace the wire. 84522361 15/06/2011

A.50.A / 72

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

If there is continuity, continue with step 6

Locate the open circuit. Using a multi-meter, check continuity between connector X-52A pin 3 and connector X-504 (F5C) X-516 (ISM) pin 1. A.

If there is no continuity, there is an open wire condition on wire 257 (Yellow) between connector X-52A pin 3 and connector X-504 (F5C) X-516 (ISM) pin 1. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC2A (EH) X-CC2A (Mech) and X-ECC2B (EH) X-CC2B (Mech) are not making a good connection at pin 13 or connectors X-52A and X-52B are not making a good connection at pin 3. Repair the connector.

Check for proper resistance of the INSTRUMENT CLUSTER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 25 and 20. A.

If resistance is 3.7 M Ω, continue with step 8.

B.

If resistance is greater than 5 M Ω, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 10 (A.30.A.88-C.20.E.10) harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) harness - Electrical schematic frame 13 (A.30.A.88-C.20.E.13)

84522361 15/06/2011

A.50.A / 73

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

3028- Engine Oil Pressure Switch - Engine Oil Pressure Low Control Module : IC Context: Diagnostic Trouble Code 3028 has an error priority of Red. The vehicle is disabled Diagnostic Trouble Code 3028. Cause: The Instrument Cluster has sensed improper oil pressure. (The fault is only activated when Engine is running and Engine Oil Pressure Switch is closed.) Possible failure modes: 1.

Mechanical problem with the oil system.

2.

Failure of Engine Oil Pressure Switch.

3.

Shorted wire in circuit.

4.

Instrument Cluster Failure.

Solution: 1.

2.

3.

4.

5.

Verify correct mechanical operation of the oil system before troubleshooting this fault electrically. Use the machine to recreate conditions for error. Use the EST to verify 3028 - Engine Oil Pressure Switch - Engine Oil Pressure Low is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for a short to ground. Disconnect connector X-510 (F5C) X-512 (ISM) from the ENGINE OIL PRESSURE SWITCH. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for continuity between connector X-510 (F5C) X-512 (ISM) pin 1, or connector X-C23 pin 18 and ground. A.

If there is no continuity, continue with step 5.

B.

If there is continuity, there is a short to ground condition on wire 255 (Yellow) between connector X-510 (F5C) X-512 (ISM) pin 1 and connector X-C23 pin 18. Continue with step 3.

Locate the short to ground. Disconnect connector X-ECC2A (EH) X-CC2A (Mech) from connector X-ECC2B (EH) X-CC2B (Mech). Disconnect connector X-52A from connector X-52B. Using a multi-meter, check for continuity between connector X-ECC2A (EH) X-CC2A (Mech) pin 8 and ground. A.

If there is no continuity, Continue with step 4.

B.

If there is continuity, there is a short to ground condition on wire 255 (Yellow) between connector X-ECC2A (EH) X-CC2A (Mech) pin 8 and connector X-C23 pin 18. Repair or replace the shorted wire.

Locate the short to ground. Using a multi-meter, check for continuity between connector X-52A pin 2 and ground. A.

If there is no continuity, there is a short to ground on wire 255 (Yellow) between connector X-52B pin 2 and X-ECC2B (EH) X-CC2B (Mech) pin 8. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 255 (Yellow) between connector X-52A pin 2 and connector X-510 (F5C) X-512 (ISM) pin 1. Repair or replace the shorted wire.

Check for proper operation of the sensor. Reconnect connector X-C23 to the INSTRUMENT CLUSTER. Leave connector X-510 (F5C) X-512 (ISM) disconnected, as this simulates a high oil pressure. Start the engine. A.

If code 3028 is no longer active, the ENGINE OIL PRESSURE SWITCH has failed. Replace the ENGINE OIL PRESSURE SWITCH.

B.

If code 3028 is still active, continue with step 6. 84522361 15/06/2011

A.50.A / 74

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

Check for proper resistance of the INSTRUMENT CLUSTER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pin 18 and 20. A.

If resistance is around 10.55 K Ω, continue with step 7.

B.

If resistance is less than 1 K Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 10 (A.30.A.88-C.20.E.10) harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) harness - Electrical schematic frame 13 (A.30.A.88-C.20.E.13)

84522361 15/06/2011

A.50.A / 75

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

3029- Engine Oil Pressure Switch - Engine Oil Pressure Switch OC Control Module : IC Context: Diagnostic Trouble Code 3029 has an error priority of Engine-Amber. There are no limitations with Diagnostic Trouble Code 3029. Cause: The Instrument Cluster has sensed improper oil pressure. (The fault is only activated when Ignition is on, Engine is off and Engine Oil Pressure Switch is open.) Possible failure modes: 1.

Open wire in circuit.

2.

Instrument Cluster Failure.

3.

Failure of Engine Oil Pressure Switch.

Solution: 1.

2.

3.

4.

5.

6.

Use the machine to recreate conditions for error. Use the EST to verify 3029 - Engine Oil Pressure Switch Engine Oil Pressure Switch OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for proper resistance in the ENGINE OIL PRESSURE SWITCH. Disconnect connector X-510 (F5C) X-512 (ISM) from the ENGINE OIL PRESSURE SWITCH. Using a multi-meter, check for resistance between ENGINE OIL PRESSURE SWITCH pin 1 and ground. A.

If resistance is infinite, the ENGINE OIL PRESSURE SWITCH has developed an open. Replace the ENGINE OIL PRESSURE SWITCH.

B.

If resistance is 0 Ω, the ENGINE OIL PRESSURE SWITCH is closed. Continue with step 3.

Check for open circuit. Disconnect connector X-510 (F5C) X-512 (ISM) from the ENGINE OIL PRESSURE SWITCH. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-510 (F5C) X-512 (ISM) pin 1 and connector X-C23 pin 18. A.

If there is continuity, continue with step 7.

B.

If there is no continuity, there is an open wire condition on wire 255 (Yellow) between connector X-510 (F5C) X-512 (ISM) pin 1 and connector X-C23 pin 18. Continue with step 4.

Locate the open circuit. Disconnect connector X-ECC2A (EH) X-CC2A (Mech) from connector X-ECC2B (EH) X-CC2B (Mech). Disconnect connector X-52A from connector X-52B. Using a multi-meter, check continuity between connector X-ECC2A (EH) X-CC2A (Mech) pin 8 and connector X-C23 pin 18. A.

If there is no continuity, there is an open wire condition on wire 255 (Yellow) between connector X-ECC2A (EH) X-CC2A (Mech) pin 8 and connector X-C23 pin 18. Repair or replace the wire.

B.

If there is continuity, continue with step 5.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC2B (EH) X-CC2B (Mech) pin 8 and connector X-52B pin 2. A.

If there is no continuity, there is an open wire condition on wire 255 (Yellow) between connector X-ECC2B (EH) X-CC2B (Mech) pin 8 and connector X-52B pin 2. Repair or replace the wire.

B.

If there is continuity, continue with step 6.

Locate the open circuit. Using a multi-meter, check continuity between connector X-52A pin 2 and connector X-510 (F5C) X-512 (ISM) pin 1. 84522361 15/06/2011

A.50.A / 76

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

7.

8.

A.

If there is no continuity, there is an open wire condition on wire 255 (Yellow) between connector X-52A pin 2 and connector X-510 (F5C) X-512 (ISM) pin 1. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC2A (EH) X-CC2A (Mech) and X-ECC2B (EH) X-CC2B (Mech) are not making a good connection at pin 8 or connectors X-52A and X-52B are not making a good connection at pin 2. Repair the connector.

Check for proper operation of the INSTRUMENT CLUSTER. Reconnect connector X-C23 to the INSTRUMENT CLUSTER. Reconnect connector X-510 (F5C) X-512 (ISM) to the ENGINE OIL PRESSURE SWITCH Start the engine. A.

If code 3029 is no longer active, continue with step 8.

B.

If code 3029 is still active, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 10 (A.30.A.88-C.20.E.10) harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) harness - Electrical schematic frame 13 (A.30.A.88-C.20.E.13)

84522361 15/06/2011

A.50.A / 77

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

3156- Engine Preheat - Glow Plug - OC Control Module : IC Context: Diagnostic Trouble Code 3156 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 3156. Cause: Instrument Cluster has sensed an open circuit condition in the Engine Preheat circuit. (The fault is only activated when Ignition is On, Preheat Commanded State is on, and Preheat Status is low.) Possible failure modes: 1.

Open wire in circuit.

2.

Failure of Engine Preheat Relay.

3.

Instrument Cluster has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 3156 - Engine Preheat - Glow Plug OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for proper operation of the ENGINE PREHEAT RELAY. Disconnect connector X-PRHT from the ENGINE PREHEAT RELAY. Connect a spare relay to connector X-PRHT. Recreate conditions for error. A.

If Trouble Code 3156 is no longer active, the ENGINE PREHEAT RELAY has failed. Replace the ENGINE PREHEAT RELAY.

B.

If Trouble Code 3156 is still active, continue with step 3.

Check for open circuit. Disconnect connector X-PRHT from the ENGINE PREHEAT RELAY. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-PRHT pin 1 and connector X-C23 pin 8. A.

If there is continuity, continue with step 6.

B.

If there is no continuity, there is an open wire condition on wire 641 (White) between connector X-PRHT pin 1 and connector X-C23 pin 8 (EH) pin 7 (Mech). Continue with step 4.

Locate the open circuit. Disconnect connector X-ECC2A (EH) X-CC2A (Mech) from connector X-ECC2B (EH) X-CC2B (Mech). Using a multi-meter, check continuity between connector X-ECC2A (EH) X-CC2A (Mech) pin 2 and connector X-C23 pin 8 (EH) pin 7 (Mech). A.

If there is no continuity, there is an open wire condition on wire 641 (White) between connector X-ECC2A (EH) X-CC2A (Mech) pin 2 and connector X-C23 pin 8 (EH) pin 7 (Mech). Repair or replace the wire.

B.

If there is continuity, continue with step 5.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC2B (EH) X-CC2B (Mech) pin 2 and connector X-PRHT pin 1. A.

If there is no continuity, there is an open wire condition on wire 641 (White) between connector X-ECC2B (EH) X-CC2B (Mech) pin 2 and connector X-PRHT pin 1. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC2A (EH) X-CC2A (Mech) and X-ECC2B (EH) X-CC2B (Mech) are not making a good connection at pin 2. Repair the connector. 84522361 15/06/2011

A.50.A / 78

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-PRHT pin 2 and ground. A.

If there is continuity, continue with step 7.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 1 and 11 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pin 7 (pin 8 for EH Machines) and pin 20. A.

If resistance is 246 K Ω, continue with step 8.

B.

If resistance is greater than 300 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 79

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

3401- Engine Start - Fuel Solenoid - STP Control Module : IC Context: Diagnostic Trouble Code 3401 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 3401. Cause: Instrument Cluster has sensed a short to positive condition in the Fuel Solenoid circuit. (The fault is only activated when Ignition is On, Fuel Solenoid Command State is Low, and Fuel Solenoid Status is low.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Instrument Cluster has internal failure.

Solution: 1.

2.

3.

4.

5.

6.

Use the machine to recreate conditions for error. Use the EST to verify 3401 - Engine Start - Fuel Solenoid STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for short to high. Disconnect connector X-517 (ISM) X-FUEL (F5C) from the FUEL SOLENOID. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-517 (ISM) X-FUEL (F5C) pin 1, or connector X-C23 pin 7 (EH) 26 (Mech) and ground. A.

If there is no voltage, continue with step 5.

B.

If there is voltage, there is a short to high source on wire 602 (White) between connector X-517 (ISM) X-FUEL (F5C) pin 1 and connector X-C23 pin 7 (EH) 26 (Mech). Continue with step 3.

Locate the short to high. Disconnect connector X-ECC1A (EH) X-CC1A (Mech) from connector X-ECC1B (EH) X-CC1B (Mech). Disconnect connector X-52A from connector X-52B. Using a multi-meter, check for voltage between connector X-517 (ISM) X-FUEL (F5C) pin 1 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 602 (White) between connector X-517 (ISM) X-FUEL (F5C) pin 1 and connector X-52A pin 6. Repair or replace the wire.

Locate the short to high. Using a multi-meter, check for voltage between connector X-52B pin 6 and ground. A.

If there is no voltage, there is a short to high source on wire 602 (White) between connector X-ECC1A (EH) X-CC1A (Mech) pin 13 and connector X-C23 pin 7 (EH) 26 (Mech). Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 602 (White) between connector X-52B pin 6 and connector X-ECC1B (EH) X-CC1B (Mech) pin 13. Repair or replace the wire.

Check for proper operation of the INSTRUMENT CLUSTER. Reconnect connector X-C23 to the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-ECC1A (EH) X-CC1A (Mech) pin 13 and ground. A.

If there is voltage, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

B.

If there is no voltage, continue with step 6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. 84522361 15/06/2011

A.50.A / 80

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 10 (A.30.A.88-C.20.E.10) harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) harness - Electrical schematic frame 13 (A.30.A.88-C.20.E.13) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 81

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

3402- Engine Start - Fuel Solenoid - OC Control Module : IC Context: Diagnostic Trouble Code 3402 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 3402. Cause: Instrument Cluster has sensed an open circuit condition in the Fuel Solenoid circuit. (The fault is only activated when Ignition is On, Fuel Solenoid Commanded State is high, and Fuel Solenoid Status is low.) Possible failure modes: 1.

Open wire in circuit.

2.

Failure of Fuel Solenoid.

3.

Instrument Cluster has internal failure.

Solution: 1.

2.

3.

4.

5.

6.

Use the machine to recreate conditions for error. Use the EST to verify 3402 - Engine Start - Fuel Solenoid OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for proper resistance in the FUEL SOLENOID. Disconnect connector X-517 (ISM) X-FUEL (F5C) from the FUEL SOLENOID. Using a multi-meter, check for resistance between FUEL SOLENOID pin 1 and ground. A.

If resistance is normal, continue with step 3.

B.

If resistance is infinite, the FUEL SOLENOID has developed an open. Replace the FUEL SOLENOID.

C.

If resistance is 0 Ω, the FUEL SOLENOID has shorted internally. Replace the FUEL SOLENOID.

Check for open circuit. Disconnect connector X-517 (ISM) X-FUEL (F5C) from the FUEL SOLENOID. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-517 (ISM) X-FUEL (F5C) pin 1 and connector X-C23 pin 7 (EH) 26 (Mech). A.

If there is continuity, continue with step 7.

B.

If there is no continuity, there is an open wire condition on wire 602 (White) between connector X-517 (ISM) X-FUEL (F5C) pin 1 and connector X-C23 pin 7 (EH) 26 (Mech). Continue with step 4.

Locate the open circuit. Disconnect connector X-ECC1A (EH) X-CC1A (Mech) from connector X-ECC1B (EH) X-CC1B (Mech). Disconnect connector X-52B from connector X-52A. Using a multi-meter, check continuity between connector X-ECC1A (EH) X-CC1A (Mech) pin 13 and connector X-C23 pin 7 (EH) 26 (Mech). A.

If there is no continuity, there is an open wire condition on wire 602 (White) between connector X-ECC1A (EH) X-CC1A (Mech) pin 13 and connector X-C23 7 (EH) 26 (Mech). Repair or replace the wire.

B.

If there is continuity, continue with step 5

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC1B (EH) X-CC1B (Mech) pin 13 and connector X-52B pin 6. A.

If there is no continuity, there is an open wire condition on wire 602 (White) between connector X-ECC1A (EH) X-CC1A (Mech) pin 13 and connector X-C23 pin 7 (EH) 26 (Mech). Repair or replace the wire.

B.

If there is continuity, continue with step 6

Locate the open circuit. Using a multi-meter, check continuity between connector X-52A pin 6 and connector X-517 (ISM) X-FUEL (F5C) pin 1. 84522361 15/06/2011

A.50.A / 82

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

7.

8.

A.

If there is no continuity, there is an open wire condition on wire 602 (White) between connector X-52A pin 6 and connector X-517 (ISM) X-FUEL (F5C) pin 1. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC1A (EH) X-CC1A (Mech) and X-ECC1B (EH) X-CC1B (Mech) are not making a good connection at pin 13, or connectors X-52B and X-52A are not making a good connection at pin 6. Repair the connector.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pin 7 (EH) 26 (Mech) and pin 20. A.

If resistance is 244 K Ω, continue with step 8.

B.

If resistance is greater than 300 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 10 (A.30.A.88-C.20.E.10) harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) harness - Electrical schematic frame 13 (A.30.A.88-C.20.E.13)

84522361 15/06/2011

A.50.A / 83

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

3403- Starter - Starter is cranked > 30s Control Module : IC Context: Diagnostic Trouble Code 3403 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 3403. Cause: Instrument Cluster has sensed that the starter is continuously energized. (The fault is only activated when Ignition is On and Starter input is high for longer than 30 seconds.) Possible failure modes: 1.

Failure of Starter Relay.

2.

Failure of Instrument Cluster.

3.

Shorted wire in circuit.

Solution: 1.

Verify correct operation of the ignition system by following Start control - Overview Ignition System (B.80.A) before troubleshooting Diagnostic Trouble Code 3403 electrically. Follow testing procedure Fuse and relay box - Testing Crank Relay Control (A.30.A) to test the CRANK RELAY K-007 before troubleshooting Diagnostic Trouble Code 3403. Check if Diagnostic Trouble Code 3404 is active.

2.

3.

4.

A.

If Diagnostic Trouble Code 3404 is active, follow the resolution procedure for 3404 - Starter - STP first. When this Diagnostic Trouble Code is no longer active, continue with this procedure.

B.

If Diagnostic Trouble Code 3404 is not active, continue with step 2.

Check for short to high. Disconnect CRANK RELAY from the MAIN POWER DISTRIBUTION FUSE BLOCK 1. Using a multi-meter, check for voltage between Crank Relay socket pin A4 on MAIN POWER DISTRIBUTION FUSE BLOCK 1 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 629 (Orange) / 626 (White) between the CRANK RELAY and the STARTER MOTOR. Continue with step 3.

Locate the short to high. Disconnect connector X-52B from connector X-52A. Using a multi-meter, check for voltage between connector X-52B pin 10 and ground. A.

If there is no voltage, there is a short to high source between connector X-52A pin 10 and the STARTER MOTOR. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 629 (Orange) / 626 (White) between connector X-52B pin 10 and MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin A4. Repair or replace the wire.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 84522361 15/06/2011

A.50.A / 84

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 10 (A.30.A.88-C.20.E.10) harness - Electrical schematic frame 12 (A.30.A.88-C.20.E.12) harness - Electrical schematic frame 13 (A.30.A.88-C.20.E.13)

84522361 15/06/2011

A.50.A / 85

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

3404- Starter - STP Control Module : IC Context: Diagnostic Trouble Code 3404 has an error priority of Red. The vehicle is disabled with Diagnostic Trouble Code 3404 if the engine is off. There are no restrictions with Diagnostic Trouble Code 3404 if the engine is running. Cause: Instrument Cluster has sensed a short to positive condition in the starting circuit. (The fault is only activated when Ignition is On and start relay commanded state is low.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Instrument Cluster has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 3404 - Starter - STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-C23 pins 9 and 20. A.

If there is no voltage, continue with step 4.

B.

If there is voltage there is a short to high source on wire 622/628/630 (White) (EH) 622/628 (White) (Mech) between connector X-C23 pin 9 and K-007 CRANK RELAY, or on wire 624 (White) between SPLICE 005 and connector X-9 pin 2. Continue with step 3.

Locate the short to high. Disconnect connector X-ECC2A (EH) X-CC2A (Mech) from connector X-ECC2B (EH) X-CC2B (Mech). Using a multi-meter, check for voltage between connector X-C23 pins 9 and 20. A.

If there is voltage, there is a short to high source on wire 622/628 (White) between connector X-ECC2A (EH) X-CC2A (Mech) pin 10 and connector X-C23 pin 9, or on wire 624 (White) between SPLICE 005 and connector X-9 pin 2. Repair or replace the wire.

B.

If there is no voltage, there is a short to high source on wire 628/630 (White) (EH) 628 (White) (Mech) between K-007 CRANK RELAY and connector X-ECC2B (EH) X-CC2B (Mech) pin 10. Repair or replace the wire.

Check for proper operation of the INSTRUMENT CLUSTER. Reconnect connector X-C23 to the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-ECC2A (EH) X-CC2A (Mech) pin 10 and ground. A.

If there is voltage, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

B.

If there is no voltage, continue with step 5.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement.

84522361 15/06/2011

A.50.A / 86

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

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. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04) harness - Electrical schematic frame 14 (A.30.A.88-C.20.E.14)

84522361 15/06/2011

A.50.A / 87

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

3405- Starter - STG / OC Control Module : IC Context: Diagnostic Trouble Code 3405 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 3405. Cause: Instrument Cluster has sensed a problem in the starting circuit. (The fault is only activated when Ignition is On and start relay commanded state is high.) Possible failure modes: 1.

Shorted or open wire in circuit.

2.

Instrument Cluster has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 3405 - Starter - STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 11.

Check for proper resistance of the INSTRUMENT CLUSTER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 9 and 20. A.

If resistance is about 244 K Ω, continue with step 3.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 300 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 11 and 20. A.

If resistance is about 603 Ω, continue with step 4.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 800 Ω, the INSTRUMENT CLUSTER has opened internally. INSTRUMENT CLUSTER.

Replace the

Check for a short to ground. Remove the CRANK RELAY from MAIN POWER DISTRIBUTION FUSE BLOCK 1. Disconnect connector X-9 from the IGNITION SWITCH. For EH Machines, also disconnect connector X-CN2B from the UCM. Using a multi-meter, check for continuity between connector MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin B4, or connector X-C23 pin 9 and ground. A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 622/628/630 (White) (EH) 622/628 (White) (Mech) between MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin B4 and connector X-C23 pin 9, or between SPLICE 005 and connector X-9 pin 2, or between SPLICE 005 and connector X-C23 pin 11. For EH Machines, also between SPLICE 102 and connector X-CN2B pin 24. Continue with step 5.

Locate the short to ground. Disconnect connector X-ECC2A (EH) X-CC2A (Mech) from connector X-ECC2B (EH) X-CC2B (Mech). Using a multi-meter, check for continuity between connector X-ECC2A (EH) X-CC2A (Mech) pin 10, or connector X-C23 pin 9 and ground. 84522361 15/06/2011

A.50.A / 88

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

9.

10.

11.

A.

If there is no continuity, there is a short to ground on wire 628/630 (White) (EH) 628 (White) (Mech) between connector MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin B4 and X-ECC2B (EH) X-CC2B (Mech) pin 10. For EH Machines, also between SPLICE 102 and connector X-CN2B pin 24.. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 628/630 (White) (EH) 628 (White) (Mech) between connector X-ECC2A (EH) X-CC2A (Mech) pin 10 and connector X-C23 pin 9, or between SPLICE 005 and connector X-C23 pin 11, or between SPLICE 005 and connector X-9 pin 2. Repair or replace the shorted wire.

Check for open circuit. Using a multi-meter, check continuity between connector MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin B4 and connector X-C23 pin 9. A.

If there is continuity, continue with step 9.

B.

If there is no continuity, there is an open wire condition on wire 622/628/630 (White) (EH) 622/628 (White) (Mech) between connector MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin B4 and connector X-C23 pin 9. Continue with step 7.

Locate the open circuit. Disconnect connector X-ECC2A (EH) X-CC2A (Mech) from connector X-ECC2B (EH) X-CC2B (Mech). Using a multi-meter, check continuity between connector X-ECC2A (EH) X-CC2A (Mech) pin 10 and connector X-C23 pin 9. A.

If there is no continuity, there is an open wire condition on wire 622/628 (White) between connector X-ECC2A (EH) X-CC2A (Mech) pin 10 and connector X-C23 pin 9. Repair or replace the wire.

B.

If there is continuity, continue with step 8.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC2B (EH) X-CC2B (Mech) pin 10 and connector MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin B4. A.

If there is no continuity, there is an open wire condition on wire 628/630 (White) (EH) 628 (White) (Mech) between connector X-ECC2B (EH) X-CC2B (Mech) pin 10 and connector MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin B4. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC2A (EH) X-CC2A (Mech) and X-ECC2B (EH) X-CC2B (Mech) are not making a good connection at pin 10. Repair the connector.

Check for open circuit. Using a multi-meter, check continuity between connector MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin B4 and connector X-C23 pin 11. A.

If there is continuity, continue with step 10.

B.

If there is no continuity, there is an open wire condition on wire 623 (White) between SPLICE 005 and connector X-C23 pin 11. Repair or replace the wire.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between MAIN POWER DISTRIBUTION FUSE BLOCK 1 pin A6 and ground. A.

If there is continuity, continue with step 11.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 1 and 4 to troubleshoot and isolate the faulty wire.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

84522361 15/06/2011

A.50.A / 89

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. Wiring Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04) harness - Electrical schematic frame 14 (A.30.A.88-C.20.E.14) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 90

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4043- Hydraulic Oil Temperature Sender - STG Control Module : IC Context: Diagnostic Trouble Code 4043 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 4043. Cause: Instrument Cluster has sensed that the Hydraulic Oil Temperature Sender has failed. (The fault is only activated when Ignition is On Start input is low and Hydraulic Oil Temperature Sender resistance is less than 25 Ω.) Possible failure modes: 1.

Failure of Hydraulic Oil Temperature Sender.

2.

Shorted wire in circuit.

3.

Failure of Instrument Cluster.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4043 - Hydraulic Oil Temperature Sender - STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for proper resistance in the HYDRAULIC OIL TEMPERATURE SENDER. Disconnect connector X-OILTMP from the HYDRAULIC OIL TEMPERATURE SENDER. Using a multi-meter, check for resistance between HYDRAULIC OIL TEMPERATURE SENDER pin 1 and ground. A.

If resistance is between 50 Ω and 9850 Ω, continue with step 3.

B.

If resistance is 0 Ω, the HYDRAULIC OIL TEMPERATURE SENDER is shorted. Replace the HYDRAULIC OIL TEMPERATURE SENDER.

Check for a short to ground. Disconnect connector X-OILTMP from the HYDRAULIC OIL TEMPERATURE SENDER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for continuity between connector X-OILTMP pin 1, or connector X-C23 pin 2 and ground. A.

If there is no continuity, continue with step 5.

B.

If there is continuity, there is a short to ground condition on wire 264 (Yellow) between connector X-OILTMP pin 1 and connector X-C23 pin 2. Continue with step 4.

Locate the short to ground. Disconnect connector X-ECC1A (EH) X-CC1A (Mech) from connector X-ECC1B (EH) X-CC1B (Mech). Using a multi-meter, check for continuity between connector X-ECC1A (EH) X-CC1A (Mech) pin 11 and ground. A.

If there is continuity, there is a short to ground condition on wire 264 (Yellow) between connector X-ECC1A (EH) X-CC1A (Mech) pin 11 and connector X-C23 pin 2. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 264 (Yellow) between connector X-ECC1B (EH) X-CC1B (Mech) pin 11 and connector X-OILTMP pin 1. Repair or replace the shorted wire.

Check for proper resistance of the INSTRUMENT CLUSTER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 2 and 20. A.

If resistance is about 3.7 M Ω, continue with step 6.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER. 84522361 15/06/2011

A.50.A / 91

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)

84522361 15/06/2011

A.50.A / 92

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4044- Hydraulic Oil Temperature Sender - OC Control Module : IC Context: Diagnostic Trouble Code 4044 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 4044. Cause: Instrument Cluster has sensed that the Hydraulic Oil Temperature Sender has failed. (The fault is only activated when Ignition is On and Start input is low and Hydraulic Oil Temperature Sender Resistance is greater than 30 K Ω.) Possible failure modes: 1.

Failure of Hydraulic Oil Temperature Sender.

2.

Open wire in circuit.

3.

Failure of Instrument Cluster.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4044 - Hydraulic Oil Temperature Sender - OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for proper resistance in the HYDRAULIC OIL TEMPERATURE SENDER. Disconnect connector X-OILTMP from the HYDRAULIC OIL TEMPERATURE SENDER. Using a multi-meter, check for resistance between HYDRAULIC OIL TEMPERATURE SENDER pin 1 and ground. A.

If resistance is between 50 Ω and 9850 Ω, continue with step 3.

B.

If resistance greater than 30 K Ω, the HYDRAULIC OIL TEMPERATURE SENDER has developed an open. Replace the HYDRAULIC OIL TEMPERATURE SENDER.

Check for open circuit. Disconnect connector X-OILTMP from the HYDRAULIC OIL TEMPERATURE SENDER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-OILTMP pin 1 and connector X-C23 pin 2. A.

If there is continuity, continue with step 6.

B.

If there is no continuity, there is an open wire condition on wire 264 (Yellow) between connector X-OILTMP pin 1 and connector X-C23 pin 2. Continue with step 4.

Locate the open circuit. Disconnect connector X-ECC1A (EH) X-CC1A (Mech) from connector X-ECC1B (EH) X-CC1B (Mech). Using a multi-meter, check continuity between connector X-ECC1A (EH) X-CC1A (Mech) pin 11 and connector X-C23 pin 2. A.

If there is no continuity, there is an open wire condition on wire 264 (Yellow) between connector X-ECC1A (EH) X-CC1A (Mech) pin 11 and connector X-C23 pin 2. Repair or replace the wire.

B.

If there is continuity, continue with step 5.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC1B (EH) X-CC1B (Mech) pin 11 and connector X-OILTMP pin 1. A.

If there is no continuity, there is an open wire condition on wire 264 (Yellow) between connector X-ECC1B (EH) X-CC1B (Mech) pin 11 and connector X-OILTMP pin 1. Repair or replace the wire.

84522361 15/06/2011

A.50.A / 93

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

If there is continuity, connectors X-ECC1A (EH) X-CC1A (Mech) and X-ECC1B (EH) X-CC1B (Mech) are not making a good connection at pin 11. Repair the connector.

Check for proper resistance of the INSTRUMENT CLUSTER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 2 and 20. A.

If resistance is about 3.7 M Ω, continue with step 7.

B.

If resistance is greater than 5 M Ω, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)

84522361 15/06/2011

A.50.A / 94

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4401- Park Brake (Mechanical Machines) - Park Brake Solenoid - OC L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Control Module : IC Context: Diagnostic Trouble Code 4401 has an error priority of Red. There are no restrictions with Diagnostic Trouble Code 4401. Cause: INSTRUMENT CLUSTER has sent a signal to the Brake Valve solenoid to energize, but the solenoid is off. (The fault is only activated when Ignition is on and solenoid output is off and Brake Commanded State is high.) Possible failure modes: 1.

Brake Valve solenoid has failed.

2.

Open wire in circuit.

3.

Instrument Cluster has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4401 - Park Brake (Mechanical Machines) - Park Brake Solenoid - OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for proper resistance in the BRAKE VALVE SOLENOID. Disconnect connector X-BRK from the BRAKE VALVE SOLENOID. Using a multi-meter to check for resistance between BRAKE VALVE SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 3.

B.

If resistance is infinite, the BRAKE VALVE SOLENOID has developed an open. Replace the BRAKE VALVE SOLENOID.

C.

If resistance is 0 Ω, the BRAKE VALVE SOLENOID has shorted internally. Replace the BRAKE VALVE SOLENOID.

Check for open circuit. Disconnect connector X-BRK from the BRAKE VALVE SOLENOID. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-BRK pin 1 and connector X-C23 pin 8. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 258 (White) between connector X-BRK pin 1 and connector X-C23 pin 8. Repair or replace the wire.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-BRK pin 2 and ground. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 1, 2, and 3 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 8 and 20. A.

If resistance is 248 K Ω, continue with step 6.

84522361 15/06/2011

A.50.A / 95

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

If resistance is greater than 300 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 96

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4402- Park Brake (Mechanical Machines) - Park Brake Solenoid STP L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Control Module : IC Context: Diagnostic Trouble Code 4402 has an error priority of Red. Vehicle is disabled with Diagnostic Trouble Code 4402. Cause: The Instrument Cluster has sent a signal to the Park Brake Valve solenoid to de-energize, but voltage is still active. (The fault is only activated when Ignition is on and Brake Commanded State is low and Brake Status is low.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Instrument Cluster has an internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 4402 - Park Brake (Mechanical Machines) - Park Brake Solenoid - STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for short to high. Disconnect connector X-BRK from the BRAKE VALVE SOLENOID. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-BRK pin 1, or connector X-C23 pin 8 and ground. A.

If there is no voltage, continue with step 3.

B.

If there is voltage, there is a short to high source on wire 258 (White) between connector X-BRK pin 1 and connector X-C23 pin 8. Repair or replace the wire.

Check for proper operation of the INSTRUMENT CLUSTER. Reconnect connector X-C23 to the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-BRK pin 1 and ground. A.

If there is voltage, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

B.

If there is no voltage, continue with step 4.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 97

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4951- Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid - STP L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Control Module : IC Context: Diagnostic Trouble Code 4951 has an error priority of Red. The vehicle is disabled with Diagnostic Trouble Code 4951. Cause: Instrument Cluster has sensed a short in the Hydraulic Interlock circuit. (The fault is only activated when Ignition is On and Hydraulic Enable Commanded state is low and Hydraulic Enable solenoid is energized.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Instrument Cluster.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 4951 - Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid - STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for short to high. Disconnect connector X-PORT_LK from the PORT LOCK. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Disconnect connector X-TELE from TELEMATICS. Using a multi-meter, check for voltage between connector X-PORT_LK pin A, or connector X-C23 pin 14 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 303/304 (White) between connector X-PORT_LK pin A and connector X-C23 pin 14. Continue with step 3.

Locate the short to high. Disconnect connector X-CC2A from connector X-CC2B. Using a multi-meter, check for voltage between connector X-PORT_LK pin A, or connector X-CC2B pin 5 and ground. A.

If there is no voltage, there is a short to high source on wire 303/304 (White) between connector X-CC2A pin 5 and connector X-C23 pin 14. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 303/304 (White) between connector X-PORT_LK pin A and connector X-CC2B pin 5, or on wire 308 (Yellow) between SPLICE 187 and connector X-TELE pin E. Repair or replace the wire.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. 84522361 15/06/2011

A.50.A / 98

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

Wiring Wiring Wiring Wiring

harness harness harness harness

-

Electrical Electrical Electrical Electrical

schematic schematic schematic schematic

frame frame frame frame

03 02 15 26

(A.30.A.88-C.20.E.03) (A.30.A.88-C.20.E.02) (A.30.A.88-C.20.E.15) (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 99

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4952- Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid - OC L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Control Module : IC NOTE: A machine with Loader Lock on will trigger trouble code 4952. This is expected. Context: Diagnostic Trouble Code 4952 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 4952. Cause: Instrument Cluster has sensed an open circuit condition in the Hydraulic Interlock circuit. (The fault is only activated when Ignition is On and Hydraulic Enable commanded state is high and Hydraulic Enable solenoid is not energized.) Possible failure modes: 1.

Open wire in circuit.

2.

Failure of Instrument Cluster.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4952 - Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid - OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for open circuit. Disconnect connector X-PORT_LK from the PORT LOCK. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-PORT_LK pin A and connector X-C23 pin 14. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 303/304 (White) between connector X-PORT_LK pin A and connector X-C23 pin 14. Continue with step 3.

Locate the open circuit. Disconnect connector X-CC2A from connector X-CC2B. Using a multi-meter, check continuity between connector X-CC2A pin 5 and connector X-C23 pin 14. A.

If there is no continuity, there is an open wire condition on wire 303/304 (White) between connector X-CC2A pin 5 and connector X-C23 pin 14. Repair or replace the wire.

B.

If there is continuity, continue with step 4

Locate the open circuit. Using a multi-meter, check continuity between connector X-CC2B pin 5 and connector X-PORT_LK pin A. A.

If there is no continuity, there is an open wire condition on wire 303/304 (White) between connector X-CC2B pin 5 and connector X-PORT_LK pin A. Repair or replace the wire.

B.

If there is continuity, connectors X-CC2A and X-CC2B are not making a good connection at pin 5. Repair the connector.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-PORT_LK pin B and ground. A.

If there is continuity, continue with step 6.

84522361 15/06/2011

A.50.A / 100

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

If there is no continuity, there is an open in the ground circuit. Use Frames 1 and 15 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 14 and 20. A.

If resistance is about 243 K Ω, continue with step 7.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 300 K Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) Wiring harness - Electrical schematic frame 15 (A.30.A.88-C.20.E.15)

84522361 15/06/2011

A.50.A / 101

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5503- Hydraulic Enable (Mechanical Machines) - EH AUX Output STP L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Control Module : IC Context: Diagnostic Trouble Code 5503 has an error priority of Red. The vehicle is disabled with Diagnostic Trouble Code 5503. Cause: Instrument Cluster has sensed a short to positive condition in the EH Aux Output circuit. (The fault is only activated when Ignition is On, Aux Output Commanded state is low and EH Aux output is energized.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Instrument Cluster.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5503 - Hydraulic Enable (Mechanical Machines) - EH AUX Output - STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high. Disconnect connector X-430 from the EH AUX PWM CONTROLLER. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-430 pin 1, or connector X-C23 pin 5 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 319 (Orange) between connector X-430 pin 1 and connector X-C23 pin 5. Continue with step 3.

Locate the short to high. Disconnect connector X-CC1A from connector X-CC1B. Using a multi-meter, check for voltage between connector X-430 pin 1, or connector X-CC1B pin 9 and ground. A.

If there is no voltage, there is a short to high source on wire 319 (Orange) between connector X-CC1A pin 9 and connector X-C23 pin 5. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 319 (Orange) between connector X-430 pin 1 and connector X-CC1B pin 9. Repair or replace the wire.

Check for proper operation of the INSTRUMENT CLUSTER. Reconnect connector X-C23 to the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-CC1A pin 9 and ground. A.

If there is voltage, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

B.

If there is no voltage, continue with step 5.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the Instrument Cluster is considered for replacement.

84522361 15/06/2011

A.50.A / 102

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) Wiring harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19)

84522361 15/06/2011

A.50.A / 103

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9003- CAN - J1939 Receive Buffer - Buffer Overflow Control Module : IC Context: Diagnostic Trouble Code 9003 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9003. Cause: The Instrument Cluster has sensed an internal memory corruption that has been automatically fixed. Possible failure modes: 1.

Memory Fault of the Instrument Cluster.

Solution: 1.

White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Use the EST to verify 9003 - CAN - J1939 Receive Buffer - Buffer Overflow is active. A.

If the fault is active, erase it with the EST.

2.

If the fault persists, it may be an indication of a potential future INSTRUMENT CLUSTER failure. Continue normal operations of the machine. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 104

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9004- Memory Error - Triple Redundant - Hour Meter - Location 1 Corrupt Control Module : IC Context: Diagnostic Trouble Code 9004 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9004. Cause: The Instrument Cluster has sensed an internal memory corruption that has been automatically fixed. Possible failure modes: 1.

Memory Fault of the Instrument Cluster.

Solution: 1.

White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Use the EST to verify 9004 - Memory Error - Triple Redundant - Hour Meter - Location 1 Corrupt is active. A.

If the fault is active, erase it with the EST.

2.

If the fault persists, it may be an indication of a potential future INSTRUMENT CLUSTER failure. Continue normal operations of the machine. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 105

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9005- Memory Error - Triple Redundant - Hour Meter - Location 2 Corrupt Control Module : IC Context: Diagnostic Trouble Code 9005 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9005. Cause: The Instrument Cluster has sensed an internal memory corruption that has been automatically fixed. Possible failure modes: 1.

Memory Fault of the Instrument Cluster.

Solution: 1.

White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Use the EST to verify 9005 - Memory Error - Triple Redundant - Hour Meter - Location 2 Corrupt is active. A.

If the fault is active, erase it with the EST.

2.

If the fault persists, it may be an indication of a potential future INSTRUMENT CLUSTER failure. Continue normal operations of the machine. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 106

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9006- Memory Error - Triple Redundant - Hour Meter - Location 3 Corrupt Control Module : IC Context: Diagnostic Trouble Code 9006 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9006. Cause: The Instrument Cluster has sensed an internal memory corruption that has been automatically fixed. Possible failure modes: 1.

Memory Fault of the Instrument Cluster.

Solution: 1.

White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Use the EST to verify 9006 - Memory Error - Triple Redundant - Hour Meter - Location 3 Corrupt is active. A.

If the fault is active, erase it with the EST.

2.

If the fault persists, it may be an indication of a potential future INSTRUMENT CLUSTER failure. Continue normal operations of the machine. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 107

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9401- Memory Error - Double Redundant - Memory Corruption Detected and repaired Control Module : IC Context: Diagnostic Trouble Code 9401 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 9401. Cause: The Instrument Cluster has sensed an internal memory corruption that has been automatically fixed. Possible failure modes: 1.

Memory Fault in the Instrument Cluster.

Solution: 1.

White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Use the EST to verify 9401 - Memory Error - Double Redundant - Memory Corruption Detected and repaired is active. A.

If the fault is active, erase it with the EST.

2.

If the fault persists, it may be an indication of a potential future INSTRUMENT CLUSTER failure. Continue normal operations of the machine. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 108

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9403- Memory Error - Double Redundant - Un-recoverable memory corruption operable Control Module : IC Context: Diagnostic Trouble Code 9403 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 9403. Cause: The Instrument Cluster has sensed an internal failure. Possible failure modes: 1.

Failure of the Instrument Cluster.

Solution: 1.

2.

Use the machine to recreate conditions for error. Use the EST to verify 9403 - Memory Error - Double Redundant - Un-recoverable memory corruption operable is active. A.

If the fault is active, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 2.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 109

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9404- Memory Error - Triple Redundant - Hour Meter - Hour Meter Failure Control Module : IC Context: Diagnostic Trouble Code 9404 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 9404. Cause: The Instrument Cluster has sensed an internal failure. Possible failure modes: 1.

Failure of the Instrument Cluster.

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 9404 - Memory Error - Triple Redundant - Hour Meter - Hour Meter Failure is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Use the EST to reset the Instrument Cluster memory and clear the fault. A.

If the fault clears, Continue normal operation.

B.

If the fault does not clear, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 110

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9405- CAN - DM1 (EH Machines) - Loss of DM1 message from UCM L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : IC Context: Diagnostic Trouble Code 9405 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 9405. Cause: The Instrument Cluster has sensed a loss of CAN message. (The fault is only activated when Ignition is On and no DM1 message is received for 5 seconds.) Possible failure modes: 1.

Shorted or Open wire in circuit.

2.

Failure of Instrument Cluster.

3.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 9405 - CAN - DM1 (EH Machines) Loss of DM1 message from UCM is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 16.

Check for open circuit. Disconnect connector X-CN1B from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-CN1B pin 34 and connector X-C23 pin 4. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 500/503/502 (Yellow) between connector X-CN1B pin 34 and connector X-C23 pin 4. Continue with step 4.

Check for open circuit. Using a multi-meter, check continuity between connector X-CN1B pin 25 and connector X-C23 pin 6. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open wire condition on wire 505/504/507 (Green) between connector X-CN1B pin 25 and connector X-C23 pin 6. Continue with step 6.

Locate the open circuit. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check continuity between connector X-ECC1A pin 3 and connector X-C23 pin 4. A.

If there is no continuity, there is an open wire condition on wire 500/503 (Yellow) between connector X-ECC1A pin 3 and connector X-C23 pin 4. Repair or replace the wire.

B.

If there is continuity, continue with step 5.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC1B pin 3 and connector X-CN1B pin 34. A.

If there is no continuity, there is an open wire condition on wire 502 (Yellow) between connector X-ECC1B pin 3 and connector X-CN1B pin 34. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC1A and X-ECC1B are not making a good connection at pin 3. Repair the connector. 84522361 15/06/2011

A.50.A / 111

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

9.

10.

11.

12.

13.

Locate the open circuit. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check continuity between connector X-ECC1A pin 4 and connector X-C23 pin 6. A.

If there is no continuity, there is an open wire condition on wire 505/504 (Green) between connector X-ECC1A pin 4 and connector X-C23 pin 6. Repair or replace the wire.

B.

If there is continuity, continue with step 7.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC1B pin 4 and connector X-CN1B pin 25. A.

If there is no continuity, there is an open wire condition on wire 507 (Green) between connector X-ECC1B pin 4 and connector X-CN1B pin 25. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC1A and X-ECC1B are not making a good connection at pin 4. Repair the connector.

Check for a short to ground. Disconnect connector X-CN1B from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Disconnect connector X-DIAG from the CAN DIAGNOSTIC CONNECTOR. Disconnect connector X-TELE from the TELEMATICS CONNECTOR. Using a multi-meter, check for continuity between connector X-CN1B pin 34, or connector X-C23 pin 4 and ground. A.

If there is no continuity, continue with step 9.

B.

If there is continuity, there is a short to ground condition on wire 500/503/502 (Yellow) between connector X-CN1B pin 25 and connector X-C23 pin 6. Continue with step 10.

Check for a short to ground. Disconnect connector X-CN1B from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for continuity between connector X-CN1B pin 25, or connector X-C23 pin 6 and ground. A.

If there is no continuity, continue with step 12.

B.

If there is continuity, there is a short to ground condition on wire 505/504/507 (Green) between connector X-CN1B pin 25 and connector X-C23 pin 6. Continue with step 11.

Locate the short to ground. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check for continuity between connector X-ECC1A pin 3, or connector X-C23 pin 4 and ground. A.

If there is no continuity, there is a short to ground on wire 502 (Yellow) between connector X-CN1B pin 34 and X-ECC1B pin 3 or between SPLICE 188 and connector X-TELE pin M, or between SPLICE 89 and connector X-DIAG pin C. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 500/503 (Yellow) between connector X-ECC1A pin 3 and connector X-C23 pin 4. Repair or replace the shorted wire.

Locate the short to ground. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check for continuity between connector X-ECC1A pin 4, or connector X-C23 pin 6 and ground. A.

If there is no continuity, there is a short to ground on wire 507 (Green) between connector X-CN1B pin 25 and X-ECC1B pin 4 or between SPLICE 189 and connector X-TELE pin N, or between SPLICE 90 and connector X-DIAG pin B. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 505/504 (Green) between connector X-ECC1A pin 3 and connector X-C23 pin 6. Repair or replace the shorted wire.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 4 and 20. A.

If resistance is about 1.19 M Ω, continue with step 13.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 1.5 M Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 6 and 20. 84522361 15/06/2011

A.50.A / 112

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

14.

15.

16.

A.

If resistance is about 1.19 M Ω, continue with step 14.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 1.5 M Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-25 and CN1A-1. A.

If resistance is normal, continue with step 15.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-34 and CN1A-1. A.

If resistance is normal, continue with step 16.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM or Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the UCM or Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 31 (A.30.A.88-C.20.E.31) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 30 (A.30.A.88-C.20.E.30)

84522361 15/06/2011

A.50.A / 113

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9406- CAN - Can Communication Lost (EH Machines) - Loss of all can communication from UCM L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : IC Context: Diagnostic Trouble Code 9406 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 9406. Cause: The Instrument Cluster has sensed a loss of CAN message. (The fault is only activated when Ignition is On and no CAN message is received for 2 seconds.) Possible failure modes: 1.

Shorted or Open wire in circuit.

2.

Failure of Instrument Cluster.

3.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 9406 - CAN - Can Communication Lost (EH Machines) - Loss of all can communication from UCM is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 16.

Check for open circuit. Disconnect connector X-CN1B from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-CN1B pin 34 and connector X-C23 pin 4. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 500/503/502 (Yellow) between connector X-CN1B pin 34 and connector X-C23 pin 4. Continue with step 4.

Check for open circuit. Using a multi-meter, check continuity between connector X-CN1B pin 25 and connector X-C23 pin 6. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open wire condition on wire 505/504/507 (Green) between connector X-CN1B pin 25 and connector X-C23 pin 6. Continue with step 6.

Locate the open circuit. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check continuity between connector X-ECC1A pin 3 and connector X-C23 pin 4. A.

If there is no continuity, there is an open wire condition on wire 500/503 (Yellow) between connector X-ECC1A pin 3 and connector X-C23 pin 4. Repair or replace the wire.

B.

If there is continuity, continue with step 5.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC1B pin 3 and connector X-CN1B pin 34. A.

If there is no continuity, there is an open wire condition on wire 502 (Yellow) between connector X-ECC1B pin 3 and connector X-CN1B pin 34. Repair or replace the wire.

84522361 15/06/2011

A.50.A / 114

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

10.

11.

12.

If there is continuity, connectors X-ECC1A and X-ECC1B are not making a good connection at pin 3. Repair the connector.

Locate the open circuit. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check continuity between connector X-ECC1A pin 4 and connector X-C23 pin 6. A.

If there is no continuity, there is an open wire condition on wire 505/504 (Green) between connector X-ECC1A pin 4 and connector X-C23 pin 6. Repair or replace the wire.

B.

If there is continuity, continue with step 7.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC1B pin 4 and connector X-CN1B pin 25. A.

If there is no continuity, there is an open wire condition on wire 507 (Green) between connector X-ECC1B pin 4 and connector X-CN1B pin 25. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC1A and X-ECC1B are not making a good connection at pin 4. Repair the connector.

Check for a short to ground. Disconnect connector X-CN1B from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Disconnect connector X-DIAG from the CAN DIAGNOSTIC CONNECTOR. Disconnect connector X-TELE from the TELEMATICS CONNECTOR. Using a multi-meter, check for continuity between connector X-CN1B pin 34, or connector X-C23 pin 4 and ground. A.

If there is no continuity, continue with step 9.

B.

If there is continuity, there is a short to ground condition on wire 500/503/502 (Yellow) between connector X-CN1B pin 25 and connector X-C23 pin 6. Continue with step 10.

Check for a short to ground. Disconnect connector X-CN1B from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for continuity between connector X-CN1B pin 25, or connector X-C23 pin 6 and ground. A.

If there is no continuity, continue with step 12.

B.

If there is continuity, there is a short to ground condition on wire 505/504/507 (Green) between connector X-CN1B pin 25 and connector X-C23 pin 6. Continue with step 11.

Locate the short to ground. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check for continuity between connector X-ECC1A pin 3, or connector X-C23 pin 4 and ground. A.

If there is no continuity, there is a short to ground on wire 502 (Yellow) between connector X-CN1B pin 34 and X-ECC1B pin 3 or between SPLICE 188 and connector X-TELE pin M, or between SPLICE 89 and connector X-DIAG pin C. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 500/503 (Yellow) between connector X-ECC1A pin 3 and connector X-C23 pin 4. Repair or replace the shorted wire.

Locate the short to ground. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check for continuity between connector X-ECC1A pin 4, or connector X-C23 pin 6 and ground. A.

If there is no continuity, there is a short to ground on wire 507 (Green) between connector X-CN1B pin 25 and X-ECC1B pin 4 or between SPLICE 189 and connector X-TELE pin N, or between SPLICE 90 and connector X-DIAG pin B. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 505/504 (Green) between connector X-ECC1A pin 3 and connector X-C23 pin 6. Repair or replace the shorted wire.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 4 and 20. A.

If resistance is about 1.19 M Ω, continue with step 13.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 1.5 M Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER. 84522361 15/06/2011

A.50.A / 115

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

13.

14.

15.

16.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 6 and 20. A.

If resistance is about 1.19 M Ω, continue with step 14.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 1.5 M Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-25 and CN1A-1. A.

If resistance is normal, continue with step 15.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-34 and CN1A-1. A.

If resistance is normal, continue with step 16.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM or Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the UCM or Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 31 (A.30.A.88-C.20.E.31) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 30 (A.30.A.88-C.20.E.30)

84522361 15/06/2011

A.50.A / 116

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9407- Memory Error - ID Errors - Unrecoverable Hardware ID Control Module : IC Context: Diagnostic Trouble Code 9407 has an error priority of Red. The vehicle is immediately disabled with Diagnostic Trouble Code 9407. Cause: The Instrument Cluster has sensed an internal failure. Possible failure modes: 1.

Failure of the Instrument Cluster.

Solution: 1.

2.

Use the machine to recreate conditions for error. Use the EST to verify 9407 - Memory Error - ID Errors Unrecoverable Hardware ID is active. A.

If the fault is active, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 2.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 117

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9408- Memory Error - ID Errors - Unrecoverable Panel ID Control Module : IC Context: Diagnostic Trouble Code 9408 has an error priority of Red. The vehicle is immediately disabled with Diagnostic Trouble Code 9408. Cause: The Instrument Cluster has sensed an internal failure. Possible failure modes: 1.

Failure of the Instrument Cluster.

Solution: 1.

2.

Use the machine to recreate conditions for error. Use the EST to verify 9408 - Memory Error - ID Errors Unrecoverable Panel ID is active. A.

If the fault is active, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 2.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 118

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1025- Throttle Sensor - out of range STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1025 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Load Control operating mode is disabled with Diagnostic Trouble Code 1025. Cause: UCM has sensed higher than normal voltage on Throttle Pin. (The fault is only activated when Ignition is on and Throttle Pin voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Throttle Position Sensor.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 1025 - Throttle Sensor - out of range STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for source of higher than normal voltage. Disconnect connector X-20 from THROTTLE POSITION SENSOR. Disconnect connector X-CN3A from the UCM. Using a multi-meter, check voltage between connector X-20 pin A, or X-CN3A pin 24, and ground. A.

If there is voltage, wire 545 (Yellow) is shorted between connector X-20 pin A and X-CN3A pin 24 to a voltage source. Repair or replace wire.

B.

If there is no voltage, continue with step 3.

Check for proper operation of the UCM. Reconnect connector X-CN3A to the UCM. Using a multi-meter, check voltage between connector X-20 pin A and ground. A.

If voltage greater than 5 V, the UCM has failed. Replace the UCM.

B.

If there is no voltage, continue with step 4.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) 84522361 15/06/2011

A.50.A / 119

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1030- Throttle Sensor - out of range STG/OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1030 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Load Control operating mode is disabled with Diagnostic Trouble Code 1030. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Engine is On and Throttle Pin voltage falls less than 0.2 V.) Possible failure modes: 1.

Failure of Throttle Position Sensor.

2.

Shorted wire in circuit.

3.

Open wire in circuit.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1030 - Throttle Sensor - out of range STG/OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for open circuit. Disconnect connector X-20 from THROTTLE POSITION SENSOR. Disconnect connector X-CN3A from UCM. Using a multi-meter, check continuity between connector X-20 pin A and connector X-CN3A pin 24. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 545 (Yellow) between connector X-20 pin A and connector X-CN3A pin 24. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-CN3A pin 24, or connector X-20 pin A and chassis ground. A.

If there is no continuity, continue with 4.

B.

If there is continuity, there is a short to ground condition on wire 545 (Yellow) between connector X-CN3A pin 24 and connector X-20 pin A. Repair or replace the open wire.

Check for proper resistance in the THROTTLE POSITION SENSOR by using a multi-meter to check for resistance between THROTTLE POSITION SENSOR pins A and B. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the THROTTLE POSITION SENSOR has developed an open, replace the THROTTLE POSITION SENSOR.

C.

If resistance is 0 Ω, the THROTTLE POSITION SENSOR has shorted internally. Replace the THROTTLE POSITION SENSOR.

Check for proper resistance in the ground circuit. Using a multi-meter, check continuity between connector X-20 pin B and ground. 84522361 15/06/2011

A.50.A / 120

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

A.

If there is continuity, continue with step 6.

B.

If there is no continuity there is an open in the ground circuit. Use Frames 1 and 25 to troubleshoot and isolate the faulty wire.

Check for a short in the UCM. Completely power down the UCM by removing all six connectors. Using a multimeter, check for resistance between UCM pins CN3A-24 and CN1A-1. A.

If resistance is around 99.6 K Ω, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 200 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 121

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1206- CAN Connection - Configuration Response Timeout L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1206 has an error priority of Amber. Limp Home Loader Hydraulics and Limp Home Ground Drive and enabled with Diagnostic Trouble Code 1206. Cause: The Instrument Cluster has not received a configuration message from the UCM within 10 seconds of startup. Possible failure modes: 1.

Failure of the Instrument Cluster.

2.

Failure of the UCM.

Solution: 1.

Use the EST to verify 1206 - CAN Connection - Configuration Response Timeout is active. A.

If the fault is active, erase it with the EST.

2.

If the fault persists, use the EST to reconfigure the machine. Continue normal operations. If the fault still persists, follow diagnostic for trouble code 9151 9151 - CAN Connection - CAN communication timed out after 5 seconds. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 122

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1207- Memory Parameters - Invalid configuration between IC and UCM L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1207 has an error priority of Amber. Limp Home Loader Hydraulics and Limp Home Ground Drive and enabled with Diagnostic Trouble Code 1207. Cause: The Instrument Cluster configuration does not match UCM configuration. Possible failure modes: 1.

Failure of the Instrument Cluster.

2.

Failure of the UCM.

Solution: 1.

Use the EST to verify 1207 - Memory Parameters - Invalid configuration between IC and UCM is active. A.

If the fault is active, erase it with the EST.

2.

If the fault persists, use the EST to reconfigure the machine. Continue normal operations. If the fault still persists, follow diagnostic for trouble code 9151 9151 - CAN Connection - CAN communication timed out after 5 seconds. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 123

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1211- Calibration Functions - Joystick Calibration not Complete L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1211 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1211. Cause: UCM has sensed that the Joystick Calibration is not complete. Possible failure modes: 1.

Calibration not complete

2.

Failure of UCM

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 1211 - Calibration Functions - Joystick Calibration not Complete is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Use the EST to perform calibration on the Joystick. Electronic service tool (EST) - H1 - Calibration procedures Joystick Calibration (A.50.A) A.

If the fault code clears, continue normal operation.

B.

If the fault code does not clear, replace the Joystick and reperform calibration. If the code persists, replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 124

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1212- Calibration Functions - Ground Drive Calibration not Complete L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1212 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1212. Cause: UCM has sensed that the Ground Drive Calibration is not complete. Possible failure modes: 1.

Calibration not complete

2.

Failure of UCM

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 1212 - Calibration Functions - Ground Drive Calibration not Complete is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Use the EST to perform calibration on the Ground Drive. Electronic service tool (EST) - H1 - Calibration procedures Ground Drive Calibration (A.50.A) A.

If the fault code clears, continue normal operation.

B.

If the fault code does not clear, replace the Ground Drive and reperform calibration. If the code persists, replace UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 125

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1213- Calibration Functions - Loader Valve Calibration not Complete L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1213 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1213. Cause: UCM has sensed that the Loader Valve Calibration is not complete. Possible failure modes: 1.

Calibration not complete

2.

Failure of UCM

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 1213 - Calibration Functions - Loader Valve Calibration not Complete is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Use the EST to perform calibration on the Loader Valve. Electronic service tool (EST) - H1 - Calibration procedures Loader Calibration (A.50.A) A.

If the fault code clears, continue normal operation.

B.

If the fault code does not clear, replace the Loader Valve and reperform calibration. If the code persists, replace UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 126

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1214- Calibration Functions - Throttle Calibration not Complete L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1214 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1214. Cause: UCM has sensed that the Throttle Calibration is not complete. Possible failure modes: 1.

Calibration not complete

2.

Failure of UCM

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 1214 - Calibration Functions - Throttle Calibration not Complete is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Use the EST to perform calibration on the Throttle. Electronic service tool (EST) - H1 - Calibration procedures Throttle Calibration (A.50.A) A.

If the fault code clears, continue normal operation.

B.

If the fault code does not clear, replace the Throttle and reperform calibration. If the code persists, replace UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 127

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1221- Health Monitor Functions - UCM - UCM Temperature / Current Draw Over Limit L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1221 has an error priority of Amber. Limp Home Hydraulics are enabled with Diagnostic Trouble Code 1221. Cause: UCM has sensed high current or high temperature in the UCM. Possible failure modes: 1.

Failure of UCM.

Solution: 1.

2.

Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify 1221 - Health Monitor Functions - UCM - UCM Temperature / Current Draw Over Limit is active. A.

If the fault is active, the UCM has failed. Replace the UCM.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 2.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 128

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1222- Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1222 has an error priority of Red. Disable Hydraulics is enabled with Diagnostic Trouble Code 1222. Cause: UCM has sensed high temperature in the UCM. Possible failure modes: 1.

Failure of UCM.

Solution: 1.

2.

Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify 1222 - Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit is active. A.

If the fault is active, the UCM has failed. Replace the UCM.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 2.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 129

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1223- Health Monitor Functions - UCM - UCM Sustained Over Current Limit L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1223 has an error priority of Red. Disable Hydraulics is enabled with Diagnostic Trouble Code 1223. Cause: UCM has sensed high current in the UCM. Possible failure modes: 1.

Failure of UCM.

Solution: 1.

2.

Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify 1223 - Health Monitor Functions - UCM - UCM Sustained Over Current Limit is active. A.

If the fault is active, the UCM has failed. Replace the UCM.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 2.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 130

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1224- Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1224 has an error priority of Red. Disable Hydraulics is enabled with Diagnostic Trouble Code 1224. Cause: UCM has sensed an internal fault in the UCM. Possible failure modes: 1.

Failure of UCM.

Solution: 1.

2.

Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify 1224 - Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault is active. A.

If the fault is active, the UCM has failed. Replace the UCM.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 2.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 131

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1225- Health Monitor Functions - UCM - EEPROM Memory Checksum Fault L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1225 has an error priority of Red. Disable Hydraulics is enabled with Diagnostic Trouble Code 1225. Cause: UCM has sensed a checksum failure in the UCM memory. Possible failure modes: 1.

Failure of UCM.

Solution: 1.

2.

Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify 1225 - Health Monitor Functions - UCM - EEPROM Memory Checksum Fault is active. A.

If the fault persists for three machine restarts, the UCM has failed. Replace the UCM.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 2.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 132

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1350- Hyd Ena switch - Implausible State (Hardwire vs CAN) L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1350 has an error priority of Amber. Loader Limp Home and Ground drive Limp Home operating modes are enabled with Diagnostic Trouble Code 1350. Cause: UCM is receiving conflicting information about the Hydraulic Enable button. (The fault is only activated when Ignition is On, crank pin is low and Hydraulic Enable button pin voltage is opposite of value from Instrument Cluster.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Open wire in circuit.

3.

Failure of Instrument Cluster.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1350 - Hyd Ena switch - Implausible State (Hardwire vs CAN) is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 9.

Check for open circuit. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Disconnect connector X-CN3A from the UCM. Using a multi-meter, check continuity between connector X-C23 pin 14 and connector X-CN3A pin 23. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 303 (White) between connector X-C23 pin 14 and connector X-CN3A pin 23. Continue with step 3.

Locate the open circuit. Disconnect connector X-ECC2B from connector X-ECC2A. Using a multi-meter, check continuity between connector X-ECC2B pin 5 and connector X-CN3A pin 23. A.

If there is no continuity, there is an open wire condition on wire 303 (White) between connector X-ECC2B pin 5 and connector X-CN3A pin 23. Repair or replace the wire.

B.

If there is continuity, continue with step 4

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC2A pin 5 and connector X-C23 pin 14. A.

If there is no continuity, there is an open wire condition on wire 303 (White) between connector X-ECC2A pin 5 and connector X-C23 pin 14. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC2B and X-ECC2A are not making a good connection at pin 5. Repair the connector.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-C23 pin 14, or connector X-CN3A pin 23 and ground. A.

If there is no continuity, continue with step 7.

84522361 15/06/2011

A.50.A / 133

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

If there is continuity, there is a short to ground condition on wire 303 (White) between connector X-C23 pin 14 and connector X-CN3A pin 23. Continue with step 6.

Locate the short to ground. Disconnect connector X-ECC2B from connector X-ECC2A. Using a multi-meter, check for continuity between connector X-ECC2B pin 5, or connector X-CN3A pin 23 and ground. A.

If there is no continuity, there is a short to ground on wire 303 (White) between connector X-C23 pin 14 and X-ECC2A pin 5. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 303 (White) between connector X-ECC2B pin 5 and connector X-CN3A pin 23. Repair or replace the shorted wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-C23 pin 14, or connector X-CN3A pin 23 and ground. A.

If there is no voltage, continue with step 9.

B.

If there is voltage, there is a short to high source on wire 303 (White) between connector X-C23 pin 14 and connector X-CN3A pin 23. Continue with step 8.

Locate the short to high. Disconnect connector X-ECC2B from connector X-ECC2A. Using a multi-meter, check for voltage between connector X-C23 pin 14, or connector X-ECC2A pin 5 and ground. A.

If there is no voltage, there is a short to high source on wire 303 (White) between connector X-ECC2B pin 5 and connector X-CN3A pin 23. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 303 (White) between connector X-C23 pin 14 and connector X-ECC2A pin 5. Repair or replace the wire.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM or Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the UCM or Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 134

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1511- Brake Lights - OC L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1511 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Brake Lights are disabled with Diagnostic Trouble Code 1511. Cause: UCM has sensed an open circuit condition on the Brake Light actuation line. (The fault is only activated when Engine is On and Brake Light voltage falls out of the range of 1 - 8 V.) Possible failure modes: 1.

Open wire in circuit.

2.

Failure of brake light.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1511 - Brake Lights - OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for proper resistance in the RH REAR ROAD LAMP Brake Lamp. Remove the Brake Lamp bulb from the RH REAR ROAD LAMP. Using a multi-meter, check for resistance across the Brake Lamp bulb. A.

If resistance is normal, replace bulb and continue with step 3.

B.

If resistance is infinite, the bulb has blown. Replace the Brake Lamp bulb.

C.

If resistance is 0 Ω, the Brake Lamp bulb has shorted internally. Replace the Brake Lamp bulb.

Check for open circuit. Disconnect connector X-44 from the RH REAR ROAD LAMP. Disconnect connector X-CN1B from the UCM. Using a multi-meter, check continuity between connector X-44 pin C and connector X-CN1B pin 29. A.

If there is continuity, continue with step 6.

B.

If there is no continuity, there is an open wire condition on wire 580/721/737/734 (Violet) between connector X-44 pin C and connector X-CN1B pin 29. Continue with step 4.

Locate the open circuit. Disconnect connector X-200 from connector X-203. Using a multi-meter, check continuity between connector X-200 pin 5 and connector X-CN1B pin 29. A.

If there is no continuity, there is an open wire condition on wire 580/721 (Violet) between connector X-200 pin 5 and connector X-CN1B pin 29. Repair or replace the wire.

B.

If there is continuity, continue with step 5.

Locate the open circuit. Using a multi-meter, check continuity between connector X-203 pin 5 and connector X-44 pin C. A.

If there is no continuity, there is an open wire condition on wire 737/734 (Violet) between connector X-203 pin 5 and connector X-44 pin C. Repair or replace the wire.

B.

If there is continuity, connectors X-200 and X-203 are not making a good connection at pin 5. Repair the connector. 84522361 15/06/2011

A.50.A / 135

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-44 pin B and ground. A.

If there is continuity, continue with step 7.

B.

If there is no continuity, there is an open in the ground circuit on wire 999/1000/950/965/967 (Black). Use Frames 16, 8, and 1 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all eight connectors. Using a multi-meter, check for resistance between UCM pins CN1B-29 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 18 (A.30.A.88-C.20.E.18)

84522361 15/06/2011

A.50.A / 136

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1512- Brake Lights - STG L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1512 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Brake Lights are disabled with Diagnostic Trouble Code 1512. Cause: UCM has sensed an short circuit condition on the Brake Light actuation line. (The fault is only activated when Brake Lights are commanded On and Brake Light current greater than 3 A.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of brake light.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1512 - Brake Lights - STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for proper resistance in the RH REAR ROAD LAMP Brake Lamp. Remove the Brake Lamp bulb from the RH REAR ROAD LAMP. Using a multi-meter, check for resistance across the Brake Lamp bulb. A.

If resistance is normal, replace bulb and continue with step 3.

B.

If resistance is infinite, the bulb has blown. Replace the Brake Lamp bulb.

C.

If resistance is 0 Ω, the Brake Lamp bulb has shorted internally. Replace the Brake Lamp bulb.

Check for a short to ground. Disconnect connector X-44 from the RH REAR ROAD LAMP. Disconnect connector X-CN1B from the UCM. Disconnect connector X-37 from the LH REAR ROAD LAMP. Disconnect connector X-39. Using a multi-meter, check for continuity between connector X-44 pin C, or connector X-CN1B pin 29 and ground. A.

If there is no continuity, continue with step 5.

B.

If there is continuity, there is a short to ground condition on wire 580/721/737/734 (Violet) between connector X-44 pin C and connector X-CN1B pin 29, or adjacent wiring. Continue with step 4.

Locate the short to ground. Disconnect connector X-200 from connector X-203. Using a multi-meter, check for continuity between connector X-200 pin 5, or connector X-CN1B pin 29, and ground. A.

If there is no continuity, there is a short to ground on wire 737/734 (Violet) between connector X-44 pin C and X-203 pin 5, or adjacent wiring. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 580/721 (Violet) between connector X-200 pin 5 and connector X-CN1B pin 29, or adjacent wiring. Repair or replace the shorted wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all eight connectors. Using a multi-meter, check for resistance between UCM pins CN1B-29 and CN1A-1. A.

If resistance is normal, continue with step 6. 84522361 15/06/2011

A.50.A / 137

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 18 (A.30.A.88-C.20.E.18)

84522361 15/06/2011

A.50.A / 138

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1513- Brake Lights - STP L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1513 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Brake Lights are disabled with Diagnostic Trouble Code 1513. Cause: UCM has sensed an short to high condition on the Brake Light actuation line. (The fault is only activated when Brake Lights are commanded Off and Brake Light voltage is greater than 8 V.) Possible failure modes: 1.

Shorted wire in circuit.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1513 - Brake Lights - STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high. Disconnect connector X-44 from the RH REAR ROAD LAMP. Disconnect connector X-CN1B from the UCM. Disconnect connector X-37 from the LH REAR ROAD LAMP. Disconnect connector X-39. Using a multi-meter, check for voltage between connector X-44 pin C, or connector X-CN1B pin 29 and ground. A.

If there is no voltage, continue with step 4.

B.

If voltage greater than 8 V, there is a short to high source on wire 580/721/737/734 (Violet) between connector X-44 pin C and connector X-CN1B pin 29, or adjacent wiring. Continue with step 3.

Locate the short to high. Disconnect connector X-200 from connector X-203. Using a multi-meter, check for voltage between connector X-44 pin C, or connector X-203 pin 5 and ground. A.

If there is no voltage, there is a short to high source on wire 580/721 (Violet) between connector X-200 pin 5 and connector X-CN1B pin 29, or adjacent wiring. Repair or replace the wire.

B.

If voltage greater than 8 V, there is a short to high source on wire 737/734 (Violet) between connector X-44 pin C and connector X-203 pin 5, or adjacent wiring. Repair or replace the wire.

Check for proper operation of the UCM. Reconnect connector X-CN1B to the UCM. Using a multi-meter, check for voltage between connector X-44 pin C and ground. A.

If voltage is greater than 8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 8 V, continue with step 5.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

84522361 15/06/2011

A.50.A / 139

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 18 (A.30.A.88-C.20.E.18)

84522361 15/06/2011

A.50.A / 140

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1521- Brake Lights - OC L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1521 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Brake Lights are disabled with Diagnostic Trouble Code 1521. Cause: UCM has sensed an open circuit condition on the Brake Light actuation line. (The fault is only activated when Engine is On and Brake Light voltage falls out of the range of 1 - 8 V.) Possible failure modes: 1.

Open wire in circuit.

2.

Failure of brake light.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1521 - Brake Lights - OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for proper resistance in the LH REAR ROAD LAMP Brake Lamp. Remove the Brake Lamp bulb from the LH REAR ROAD LAMP. Using a multi-meter, check for resistance across the Brake Lamp bulb. A.

If resistance is normal, replace bulb and continue with step 3.

B.

If resistance is infinite, the bulb has blown. Replace the Brake Lamp bulb.

C.

If resistance is 0 Ω, the Brake Lamp bulb has shorted internally. Replace the Brake Lamp bulb.

Check for open circuit. Disconnect connector X-37 from the LH REAR ROAD LAMP. Disconnect connector X-CN1B from the UCM. Using a multi-meter, check continuity between connector X-37 pin C and connector X-CN1B pin 30. A.

If there is continuity, continue with step 6.

B.

If there is no continuity, there is an open wire condition on wire 579/721/737/732 (Violet) between connector X-37 pin C and connector X-CN1B pin 30. Continue with step 4.

Locate the open circuit. Disconnect connector X-200 from connector X-203. Using a multi-meter, check continuity between connector X-200 pin 5 and connector X-CN1B pin 30. A.

If there is no continuity, there is an open wire condition on wire 579/721 (Violet) between connector X-200 pin 5 and connector X-CN1B pin 30. Repair or replace the wire.

B.

If there is continuity, continue with step 5.

Locate the open circuit. Using a multi-meter, check continuity between connector X-203 pin 5 and connector X-37 pin C. A.

If there is no continuity, there is an open wire condition on wire 737/732 (Violet) between connector X-203 pin 5 and connector X-37 pin C. Repair or replace the wire.

B.

If there is continuity, connectors X-200 and X-203 are not making a good connection at pin 5. Repair the connector. 84522361 15/06/2011

A.50.A / 141

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-44 pin B and ground. A.

If there is continuity, continue with step 7.

B.

If there is no continuity, there is an open in the ground circuit on wire 998/1000/950/965/967 (Black). Use Frames 16, 8, and 1 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all eight connectors. Using a multi-meter, check for resistance between UCM pins CN1B-30 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 18 (A.30.A.88-C.20.E.18)

84522361 15/06/2011

A.50.A / 142

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1522- Brake Lights - STG L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1522 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Brake Lights are disabled with Diagnostic Trouble Code 1522. Cause: UCM has sensed an short circuit condition on the Brake Light actuation line. (The fault is only activated when Brake Lights are commanded On and Brake Light current greater than 3 A.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of brake light.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1522 - Brake Lights - STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for proper resistance in the LH REAR ROAD LAMP Brake Lamp. Remove the Brake Lamp bulb from the LH REAR ROAD LAMP. Using a multi-meter, check for resistance across the Brake Lamp bulb. A.

If resistance is normal, replace bulb and continue with step 3.

B.

If resistance is infinite, the bulb has blown. Replace the Brake Lamp bulb.

C.

If resistance is 0 Ω, the Brake Lamp bulb has shorted internally. Replace the Brake Lamp bulb.

Check for a short to ground. Disconnect connector X-37 from the LH REAR ROAD LAMP. Disconnect connector X-CN1B from the UCM. Disconnect connector X-44 from the RH REAR ROAD LAMP. Disconnect connector X-39. Using a multi-meter, check for continuity between connector X-37 pin C, or connector X-CN1B pin 30 and ground. A.

If there is no continuity, continue with step 5.

B.

If there is continuity, there is a short to ground condition on wire 579/721/737/732 (Violet) between connector X-37 pin C and connector X-CN1B pin 30, or adjacent wiring. Continue with step 4.

Locate the short to ground. Disconnect connector X-200 from connector X-203. Using a multi-meter, check for continuity between connector X-200 pin 5, or connector X-CN1B pin 30, and ground. A.

If there is no continuity, there is a short to ground on wire 737/732 (Violet) between connector X-37 pin C and X-203 pin 5, or adjacent wiring. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 579/721 (Violet) between connector X-200 pin 5 and connector X-CN1B pin 30, or adjacent wiring. Repair or replace the shorted wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all eight connectors. Using a multi-meter, check for resistance between UCM pins CN1B-30 and CN1A-1. A.

If resistance is normal, continue with step 6. 84522361 15/06/2011

A.50.A / 143

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 18 (A.30.A.88-C.20.E.18)

84522361 15/06/2011

A.50.A / 144

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1523- Brake Lights - STP L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1523 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Brake Lights are disabled with Diagnostic Trouble Code 1523. Cause: UCM has sensed an short to high condition on the Brake Light actuation line. (The fault is only activated when Brake Lights are commanded Off and Brake Light voltage is greater than 8 V.) Possible failure modes: 1.

Shorted wire in circuit.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1523 - Brake Lights - STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high. Disconnect connector X-37 from the LH REAR ROAD LAMP. Disconnect connector X-CN1B from the UCM. Disconnect connector X-44 from the RH REAR ROAD LAMP. Disconnect connector X-39. Using a multi-meter, check for voltage between connector X-37 pin C, or connector X-CN1B pin 30 and ground. A.

If there is no voltage, continue with step 4.

B.

If voltage greater than 8 V, there is a short to high source on wire 579/721/737/732 (Violet) between connector X-37 pin C and connector X-CN1B pin 30, or adjacent wiring. Continue with step 3.

Locate the short to high. Disconnect connector X-200 from connector X-203. Using a multi-meter, check for voltage between connector X-37 pin C, or connector X-203 pin 5 and ground. A.

If there is no voltage, there is a short to high source on wire 579/721 (Violet) between connector X-200 pin 5 and connector X-CN1B pin 30, or adjacent wiring. Repair or replace the wire.

B.

If voltage greater than 8 V, there is a short to high source on wire 737/732 (Violet) between connector X-37 pin C and connector X-203 pin 5, or adjacent wiring. Repair or replace the wire.

Check for proper operation of the UCM. Reconnect connector X-CN1B to the UCM. Using a multi-meter, check for voltage between connector X-37 pin C and ground. A.

If voltage is greater than 8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 8 V, continue with step 5.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

84522361 15/06/2011

A.50.A / 145

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 18 (A.30.A.88-C.20.E.18)

84522361 15/06/2011

A.50.A / 146

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1532- Backup Alarm - STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1532 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Backup Alarm is disabled with Diagnostic Trouble Code 1532. Cause: UCM has sensed improper current from the Backup Alarm. (The fault is only activated with both pumps in reverse and Backup Alarm solenoid output current is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 1532 - Backup Alarm - STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for a short to ground. Disconnect connector X-BKUP-PWR from the BACKUP ALARM. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check for continuity between connector X-BKUP-PWR pin 1, or connector X-CN3B pin 18 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 895 (White) between connector X-BKUPPWR pin 1 and connector X-CN3B pin 18. Repair or replace the wire.

Check for proper resistance in the BACKUP ALARM. Disconnect connector X-BKUP-GND from the BACKUP ALARM. Using a multi-meter to check for resistance between BACKUP ALARM pins 1 and 1. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the BACKUP ALARM has developed an open. Replace the BACKUP ALARM.

C.

If resistance is 0 Ω, the BACKUP ALARM has shorted internally. Replace the BACKUP ALARM.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-18 and CN1A-1. A.

If resistance is normal, continue with step 5.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 84522361 15/06/2011

A.50.A / 147

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 148

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1533- Backup Alarm - STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1533 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Backup Alarm is disabled with Diagnostic Trouble Code 1533. Cause: UCM has sensed that the Backup Alarm solenoid output does not agree with the desired Backup Alarm status. (The fault is only activated with pumps not in reverse and Backup Alarm solenoid output voltage is greater than 8 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 1533 - Backup Alarm - STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for short to high. Disconnect connector X-BKUP-PWR from the BACKUP ALARM SOLENOID. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check for voltage between connector X-BKUP-PWR pin 1, or connector X-CN3B pin 18 and ground. A.

If there is no voltage, continue with step 3.

B.

If there is voltage, there is a short to high source on wire 895 (White) between connector X-BKUP-PWR pin 1 and connector X-CN3B pin 18. Repair or replace the wire.

Check for proper operation of the UCM. Reconnect connector X-CN3B to the UCM. Using a multi-meter, check for voltage between connector X-BKUP-PWR pin 1 and ground. A.

If voltage is greater than 8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 8 V, continue with step 4.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 149

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1900- UCM - UCM Ground Fault L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1900 has an error priority of Red. All hydraulics are disabled with Diagnostic Trouble Code 1900. Cause: UCM has sensed low current in the UCM ground line. (The fault is only activated when Ignition is On and there is a high resistance in the UCM ground line.) Possible failure modes: 1.

Wire or connection in circuit.

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 1900 - UCM - UCM Ground Fault is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check for proper resistance in the ground circuit. Disconnect connector X-CN1A from the UCM. Using a multimeter, check for continuity between connector X-CN1A pin 7 and negative battery post. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open in the ground circuit. Ensure the battery post is clean. See Battery - Check Maintenance Free (A.30.A) for battery check procedure. Ensure there is a clean connection between connector X-CN1A and the UCM at pin 7.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 150

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1901- UCM - UCM Supply Voltage HIGH L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1901 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 1901. Cause: UCM has sensed that the supply voltage is high. (The fault is only activated when Ignition is On, and voltage is greater than 16 V.) Possible failure modes: 1.

Problem with battery or charging system.

2.

Failure of UCM.

Solution: 1.

2.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Use the machine to recreate conditions for error. Use the EST to verify 1901 - UCM - UCM Supply Voltage HIGH is active. A.

If the fault is active, replace the UCM.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 2.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 151

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1902- UCM - UCM Supply Voltage LOW L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1902 has an error priority of White. There are no restrictions with Diagnostic Trouble Code 1902. Cause: UCM has sensed that a UCM input voltage is low. (The fault is only activated when Ignition is On and UCM input voltage is less than 11.5 V.) Possible failure modes: 1.

Blown fuse.

2.

Open wire in circuit.

3.

Shorted wire in circuit.

4.

Failure of UCM.

Solution: 1.

White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Follow procedure for Trouble Code 1903 for resolution. 1903 - UCM - UCM Supply Voltage Below Operational Limit

84522361 15/06/2011

A.50.A / 152

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1904- UCM - Rail 12VB - 5V regulators supply Input Power OFF L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1904 has an error priority of Red. All Hydraulics are disabled with Diagnostic Trouble Code 1904. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Failure of UCM Power Relay

2.

Open wire in circuit

3.

Shorted wire in circuit

4.

Failure of UCM

Solution: 1.

2.

3.

4.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1904 - UCM - Rail 12VB - 5V regulators supply Input Power OFF is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for proper operation of the UCM POWER RELAY. If a spare relay is not available, disconnect the OPTION RELAY from the ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Connect the substitute relay to the UCM Power Relay socket on ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Start the engine. A.

If Trouble Code 1904 is no longer active, the UCM POWER RELAY has failed. Replace the UCM POWER RELAY.

B.

If Trouble Code 1904 is still active, remove the relay and continue with step 3.

Check for open circuit. Disconnect connector X-CN1A from the UCM. Using a multi-meter, check continuity between connector X-CN1A pin 26 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A7. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 240/241/190 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A7 and connector X-CN1A pin 26. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A7 and ground. A.

If there is no continuity, continue with step 5.

B.

If there is continuity, there is a short to ground condition on wire 240/241/190 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A7 and connector X-CN1A pin 26, or on the connecting distribution wiring. Use frames 1, 5, and 26 to repair or replace the wire. 84522361 15/06/2011

A.50.A / 153

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5.

6.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1A-26 and CN1A-1. A.

If resistance is normal, continue with step 6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05) Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 154

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1905- UCM - 5VREF1 Sensor Supply Voltage Out of Range L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1905 has an error priority of Red. All Hydraulics are disabled with Diagnostic Trouble Code 1905. Cause: UCM has sensed that the sensor supply voltage is out of range. (The fault is only activated when Ignition is On and pin voltage falls out of the range of 4.8 V and 5.2 V.) Possible failure modes: 1.

Problem with battery or charging system.

2.

Failure of UCM.

Solution: 1.

2.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify 1905 UCM - 5VREF1 Sensor Supply Voltage Out of Range is active. A.

If the fault is active, the UCM has failed. Replace the UCM.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 2.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 155

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1906- UCM - 5VREF3 Sensor Supply Voltage Out of Range L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1906 has an error priority of Red. All Hydraulics are disabled with Diagnostic Trouble Code 1906. Cause: UCM has sensed that the sensor supply voltage is out of range. (The fault is only activated when Ignition is On and pin voltage falls out of the range of 4.8 V and 5.2 V.) Possible failure modes: 1.

Problem with battery or charging system.

2.

Failure of UCM.

Solution: 1.

2.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Turn off the machine. Restart the machine and recreate conditions for error. Use the EST to verify 1906 UCM - 5VREF3 Sensor Supply Voltage Out of Range is active. A.

If the fault is active, the UCM has failed. Replace the UCM.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 2.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation.

84522361 15/06/2011

A.50.A / 156

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1907- UCM - Rail 12VF1 - Aux Retract Input Power OFF L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1907 has an error priority of Amber. Disable Aux operating mode is enabled with Diagnostic Trouble Code 1907. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Open wire in circuit.

2.

Shorted wire in circuit.

3.

Blown fuse.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1907 - UCM - Rail 12VF1 - Aux Retract Input Power OFF is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for blown fuse. Remove fuse F-18 from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Using a multimeter, check for resistance across the fuse. A.

If resistance is 0 Ω, continue with step 3.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for open circuit. Disconnect connector X-CN1B from the UCM. Using a multi-meter, check continuity between connector X-CN1B pin 26 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B2. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 177/128 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B2 and connector X-CN1B pin 26. Repair or replace the wire.

Check for open circuit. Disconnect connector X-CN1B from the UCM. Using a multi-meter, check continuity between connector X-CN1B pin 27 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B2. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 126 (Orange) between SPLICE 109 and connector X-CN1B pin 27. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B2 and ground. A.

If there is no continuity, continue with step 6. 84522361 15/06/2011

A.50.A / 157

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

6.

7.

8.

If there is continuity, there is a short to ground condition on wire 177/128 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B2 and connector X-CN1B pin 26, or on wire 126 (Orange) between SPLICE 109 and connector X-CN1B pin 27. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-26 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-27 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)

84522361 15/06/2011

A.50.A / 158

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1908- UCM - Rail 12VF2 - Bucket Extend Input Power OFF L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1908 has an error priority of Red. Disable Bucket operating mode is enabled with Diagnostic Trouble Code 1908. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Blown fuse.

2.

Open wire in circuit.

3.

Shorted wire in circuit.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1908 - UCM - Rail 12VF2 - Bucket Extend Input Power OFF is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 9.

Check for blown fuse. Remove fuse F-19 from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Using a multimeter, check for resistance across the fuse. A.

If resistance is 0 Ω, continue with step 3.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for open circuit. Disconnect connector X-CN4A from the UCM. Using a multi-meter, check continuity between connector X-CN4A pin 1 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin D4. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 176/0060 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin D4 and connector X-CN4A pin 1. Repair or replace the wire.

Check for open circuit. Using a multi-meter, check continuity between connector X-CN4A pin 8 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin D4. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 0061 (Orange) between SPLICE 111 and connector X-CN4A pin 8. Repair or replace the wire.

Check for a short to ground. Check if Diagnostic Trouble Code 1913 is active. A.

If Diagnostic Trouble Code 1913 is active, follow the "short to ground" portion of 1913 - UCM - Rail 12VS1 - Bucket Curl Input Power OFF in conjunction with step 6 of this procedure. 84522361 15/06/2011

A.50.A / 159

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

If Diagnostic Trouble Code 1913 is not active, continue with step 7.

Check for a short to ground. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin D4 and ground. A.

If there is no continuity, continue with step 7.

B.

If there is continuity, there is a short to ground condition on wire 176/0060 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin D4 and connector X-CN4A pin 1, or on wire 0061 (Orange) between SPLICE 111 and connector X-CN4A pin 8. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN4A-1 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Using a multi-meter, check for resistance between UCM pins CN4A-8 and CN1A-1. A.

If resistance is normal, continue with step 9.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)

84522361 15/06/2011

A.50.A / 160

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1909- UCM - Rail 12VF3 - Boom Raise/Lower Input Power OFF L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1909 has an error priority of Red. Disable Boom operating mode is enabled with Diagnostic Trouble Code 1909. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Blown fuse.

2.

Open wire in circuit.

3.

Shorted wire in circuit.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1909 - UCM - Rail 12VF3 - Boom Raise/Lower Input Power OFF is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for blown fuse. Remove fuse F-22 from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Using a multimeter, check for resistance across the fuse. A.

If resistance is 0 Ω, continue with step 3.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for open circuit. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check continuity between connector X-CN2B pin 9 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B6. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 178/154 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B6 and connector X-CN2B pin 9. Repair or replace the wire.

Check for open circuit. Using a multi-meter, check continuity between connector X-CN2B pin 17 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B6. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 158 (Orange) between SPLICE 110 and connector X-CN2B pin 17. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B6 and ground. A.

If there is no continuity, continue with step 6. 84522361 15/06/2011

A.50.A / 161

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

6.

7.

8.

If there is continuity, there is a short to ground condition on wire 178/154 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B6 and connector X-CN2B pin 9, or on wire 158 (Orange) between SPLICE 110 and connector X-CN2B pin 17. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2B-9 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Using a multi-meter, check for resistance between UCM pins CN2B-17 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)

84522361 15/06/2011

A.50.A / 162

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1911- UCM - Rail 12VH1 - Left & Right Pmp Reverse Input Power OFF L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1911 has an error priority of Red. Disable Reverse Ground Drive is enabled with Diagnostic Trouble Code 1911. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Blown fuse.

2.

Open wire in circuit.

3.

Shorted wire in circuit.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1911 - UCM - Rail 12VH1 - Left & Right Pmp Reverse Input Power OFF is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for blown fuse. Remove fuse F-17 from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Using a multimeter, check for resistance across the fuse. A.

If resistance is 0 Ω, continue with step 3.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for open circuit. Disconnect connector X-CN2A from the UCM. Using a multi-meter, check continuity between connector X-CN2A pin 2 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A6. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 122/164 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A6 and connector X-CN2A pin 2. Repair or replace the wire.

Check for open circuit. Using a multi-meter, check continuity between connector X-CN2A pin 3 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A6. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 165 (Orange) between SPLICE 152 and connector X-CN2A pin 3. Repair or replace the wire.

Check for a short to ground. Disconnect connector X-94 from the LH PUMP SWASH PLATE SENSOR. Disconnect connector X-93 from the RH PUMP SWASH PLATE SENSOR. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A6 and ground. 84522361 15/06/2011

A.50.A / 163

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 122/164 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A6 and connector X-CN2A pin 2, or on wire 165 (Orange) between SPLICE 152 and connector X-CN2A pin 3, or on wire 102 (Orange) between SPLICE 152 and connector X-94 or connector X-93. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2A-2 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Using a multi-meter, check for resistance between UCM pins CN2A-3 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05) Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27)

84522361 15/06/2011

A.50.A / 164

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1912- UCM - Rail 12VM - Lft & Rgt Brake Lights & Aux Extend Input Power OFF L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1912 has an error priority of Amber. Disable Aux operating mode is enabled with Diagnostic Trouble Code 1912. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Blown fuse.

2.

Open wire in circuit.

3.

Shorted wire in circuit.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1912 - UCM - Rail 12VM - Lft & Rgt Brake Lights & Aux Extend Input Power OFF is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for blown fuse. Remove fuse F-15 from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Using a multimeter, check for resistance across the fuse. A.

If resistance is 0 Ω, continue with step 3.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for open circuit. Disconnect connector X-CN1B from the UCM. Using a multi-meter, check continuity between connector X-CN1B pin 32 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A2. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 172/201 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A2 and connector X-CN1B pin 32. Repair or replace the wire.

Check for open circuit. Using a multi-meter, check continuity between connector X-CN1B pin 31 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A2. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 166 (Orange) between SPLICE 113 and connector X-CN1B pin 31. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A2 and ground. 84522361 15/06/2011

A.50.A / 165

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 172/201 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A2 and connector X-CN1B pin 32, or on wire 166 (Orange) between SPLICE 113 and connector X-CN1B pin 31. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-31 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Using a multi-meter, check for resistance between UCM pins CN1B-32 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)

84522361 15/06/2011

A.50.A / 166

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1913- UCM - Rail 12VS1 - Bucket Curl Input Power OFF L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1913 has an error priority of Red. Disable Bucket operating mode is enabled with Diagnostic Trouble Code 1913. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Blown fuse.

2.

Open wire in circuit.

3.

Shorted wire in circuit.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1913 - UCM - Rail 12VS1 - Bucket Curl Input Power OFF is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 9.

Check for blown fuse. Remove fuse F-19 from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Using a multimeter, check for resistance across the fuse. A.

If resistance is 0 Ω, continue with step 3.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for open circuit. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check continuity between connector X-CN3B pin 8 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin D4. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 176/142 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin D4 and connector X-CN3B pin 8. Repair or replace the wire.

Check for open circuit. Using a multi-meter, check continuity between connector X-CN3B pin 9 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin D4. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 147 (Orange) between SPLICE 111 and connector X-CN3B pin 9. Repair or replace the wire.

Check for a short to ground. Check if Diagnostic Trouble Code 1908 is active. A.

If Diagnostic Trouble Code 1908 is active, follow the "short to ground" portion of 1908 - UCM - Rail 12VF2 - Bucket Extend Input Power OFF in conjunction with step 6 of this procedure. 84522361 15/06/2011

A.50.A / 167

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

If Diagnostic Trouble Code 1908 is not active, continue with step 7.

Check for a short to ground. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin D4 and ground. A.

If there is no continuity, continue with step 7.

B.

If there is continuity, there is a short to ground condition on wire 176/142 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin D4 and connector X-CN3B pin 8, or on wire 147 (Orange) between SPLICE 111 and connector X-CN3B pin 9. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-8 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Using a multi-meter, check for resistance between UCM pins CN3B-9 and CN1A-1. A.

If resistance is normal, continue with step 9.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)

84522361 15/06/2011

A.50.A / 168

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1914- UCM - Rail 12VS2 - Backup Alarm Input Power OFF L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1914 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1914. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Blown fuse.

2.

Open wire in circuit.

3.

Shorted wire in circuit.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1914 - UCM - Rail 12VS2 - Backup Alarm Input Power OFF is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for blown fuse. Remove fuse F-7 from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 1. Using a multimeter, check for resistance across the fuse. A.

If resistance is 0 Ω, continue with step 3.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for open circuit. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check continuity between connector X-CN3B pin 3 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 1 pin B2. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 167 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 1 pin B2 and connector X-CN3B pin 3. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 1 pin B2 and ground. A.

If there is no continuity, continue with step 5.

B.

If there is continuity, there is a short to ground condition on wire 167 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 1 pin B2 and connector X-CN3B pin 3. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-3 and CN1A-1. 84522361 15/06/2011

A.50.A / 169

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

A.

If resistance is normal, continue with step 6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)

84522361 15/06/2011

A.50.A / 170

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1915- UCM - Rail 12VT1 - Two Speed Input Power OFF L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1915 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 1915. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Blown fuse.

2.

Open wire in circuit.

3.

Shorted wire in circuit.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1915 - UCM - Rail 12VT1 - Two Speed Input Power OFF is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for blown fuse. Remove fuse F-27 from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Using a multimeter, check for resistance across the fuse. A.

If resistance is 0 Ω, continue with step 3.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for open circuit. Disconnect connector X-CN3A from the UCM. Using a multi-meter, check continuity between connector X-CN3A pin 7 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin E4. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 179/170 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin E4 and connector X-CN3A pin 7. Repair or replace the wire.

Check for open circuit. Using a multi-meter, check continuity between connector X-CN3A pin 13 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin E4. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 171 (Orange) between SPLICE 115 and connector X-CN3A pin 13. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin E4 and ground. A.

If there is no continuity, continue with step 6. 84522361 15/06/2011

A.50.A / 171

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

6.

7.

8.

If there is continuity, there is a short to ground condition on wire 179/170 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin E4 and connector X-CN3A pin 7, or on wire 171 (Orange) between SPLICE 115 and connector X-CN3A pin 13. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3A-7 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Using a multi-meter, check for resistance between UCM pins CN3A-13 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)

84522361 15/06/2011

A.50.A / 172

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1916- UCM - Rail 12VU1 - Right & Left Pumps Forward Input Power OFF L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1916 has an error priority of Red. Disable Forward Ground Drive is enabled with Diagnostic Trouble Code 1916. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Blown fuse.

2.

Open wire in circuit.

3.

Shorted wire in circuit.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1916 - UCM - Rail 12VU1 - Right & Left Pumps Forward Input Power OFF is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for blown fuse. Remove fuse F-21 from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Using a multimeter, check for resistance across the fuse. A.

If resistance is 0 Ω, continue with step 3.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for open circuit. Disconnect connector X-CN3A from the UCM. Using a multi-meter, check continuity between connector X-CN3A pin 21 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B4. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 120 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B4 and connector X-CN3A pin 21. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B4 and ground. A.

If there is no continuity, continue with step 5.

B.

If there is continuity, there is a short to ground condition on wire 120 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin B4 and connector X-CN3A pin 21. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. 84522361 15/06/2011

A.50.A / 173

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

Using a multi-meter, check for resistance between UCM pins CN3A-21 and CN1A-1.

6.

A.

If resistance is normal, continue with step 6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)

84522361 15/06/2011

A.50.A / 174

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1917- UCM - Rail 12VU2 - Park Brake Solenoid Input Power OFF L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 1917 has an error priority of Red. Disable Ground Drive is enabled with Diagnostic Trouble Code 1917. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Blown fuse.

2.

Open wire in circuit.

3.

Shorted wire in circuit.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1917 - UCM - Rail 12VU2 - Park Brake Solenoid Input Power OFF is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for blown fuse. Remove fuse F-16 from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Using a multimeter, check for resistance across the fuse. A.

If resistance is 0 Ω, continue with step 3.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for open circuit. Disconnect connector X-CN3A from the UCM. Using a multi-meter, check continuity between connector X-CN3A pin 2 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A4. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 185/168 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A4 and connector X-CN3A pin 2. Repair or replace the wire.

Check for open circuit. Using a multi-meter, check continuity between connector X-CN3A pin 3 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A4. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 169 (Orange) between SPLICE 114 and connector X-CN3A pin 3. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A4 and ground. A.

If there is no continuity, continue with step 6. 84522361 15/06/2011

A.50.A / 175

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

6.

7.

8.

If there is continuity, there is a short to ground condition on wire 185/168 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin A4 and connector X-CN3A pin 2, or on wire 169 (Orange) between SPLICE 114 and connector X-CN3A pin 3. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3A-2 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Using a multi-meter, check for resistance between UCM pins CN3A-3 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)

84522361 15/06/2011

A.50.A / 176

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

3154- Engine Preheat - Glow Plug - STP Control Module : UCM Context: Fault code 3154 has an error priority of Engine-Amber. There are no restrictions with Fault code 3154. Cause: The Instrument Cluster has determined that the Glow Plug circuit has a short to positive condition. (The fault is only activated when Ignition is on, the Preheat Command State is low and the Preheat Status is low.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Instrument Cluster has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 3154 - Engine Preheat - Glow Plug STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high. Disconnect connector X-PRHT from the ENGINE PREHEAT RELAY. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-PRHT pin 1 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 641 (White) between connector X-PRHT pin 1 and connector X-C23 pin 8 (EH) pin 7 (Mech). Continue with step 3.

Locate the short to high. Disconnect connector X-ECC2A (EH) X-CC2A (Mech) from connector X-ECC2B (EH) X-CC2B (Mech). Using a multi-meter, check for voltage between connector X-PRHT pin 1 and ground. A.

If there is no voltage, there is a short to high source on wire 641 (White) between connector X-ECC2B (EH) X-CC2B (Mech) pin 2 and connector X-C23 pin 8 (EH) pin 7 (Mech). Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 641 (White) between connector X-PRHT pin 1 and connector X-ECC2B (EH) X-CC2B (Mech) pin 2. Repair or replace the wire.

Check for proper operation of the INSTRUMENT CLUSTER. Reconnect connector X-C23 to the INSTRUMENT CLUSTER. Using a multi-meter, check for voltage between connector X-ECC2A (EH) X-CC2A (Mech) pin 2 and ground. A.

If there is voltage, the INSTRUMENT CLUSTER has failed. Replace the INSTRUMENT CLUSTER.

B.

If there is no voltage, continue with step 5.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) 84522361 15/06/2011

A.50.A / 177

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11) Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 178

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4055- Park Brake Valve (On/Off) - Solenoid Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4055 has an error priority of Red. Ground Drive operating mode is disabled with Diagnostic Trouble Code 4055. Cause: UCM has sensed an open in the solenoid supply. (The fault is only activated when Engine is on and UCM pin voltage is between 1 - 8 V.) Possible failure modes: 1.

Park Brake Valve solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4055 - Park Brake Valve (On/Off) Solenoid Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for proper resistance in the BRAKE VALVE SOLENOID. Disconnect connector X-BRK from the BRAKE VALVE SOLENOID. Using a multi-meter to check for resistance between BRAKE VALVE SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 2.

B.

If resistance is infinite, the BRAKE VALVE SOLENOID has developed an open. Replace the BRAKE VALVE SOLENOID.

C.

If resistance is 0 Ω, the BRAKE VALVE SOLENOID has shorted internally. Replace the BRAKE VALVE SOLENOID.

Check for open circuit. Disconnect connector X-BRK from the BRAKE VALVE SOLENOID. Disconnect connector X-CN3A from the UCM. Using a multi-meter, check continuity between connector X-BRK pin 1 and connector X-CN3A pin 4. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 258 (White) between connector X-BRK pin 1 and connector X-CN3A pin 4. Repair or replace the wire.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-BRK pin 2 and ground. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 1, 26, and 28 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3A-4 and CN1A-1. A.

If resistance is normal, continue with step 6. 84522361 15/06/2011

A.50.A / 179

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 28 (A.30.A.88-C.20.E.28)

84522361 15/06/2011

A.50.A / 180

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4056- Park Brake Valve (On/Off) - Solenoid Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4056 has an error priority of Red. Ground Drive operating mode is disabled with Diagnostic Trouble Code 4056. Cause: The UCM has sent a signal to the Park Brake Valve solenoid to energize, but there is no voltage detected. (The fault is only activated when Hydraulics are Enabled and the Park Brake is disabled and Park Brake Valve solenoid output current is high.) Possible failure modes: 1.

Park Brake Valve solenoid failed.

2.

Shorted wire in circuit.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4056 - Park Brake Valve (On/Off) Solenoid Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for a short to ground. Disconnect connector X-CN3A from the UCM. Disconnect connector X-BRK from the BRAKE VALVE SOLENOID. Using a multi-meter, check for continuity between connector X-BRK pin 1, or connector X-CN3A pin 4 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 258 (White) between connector X-BRK pin 1 and connector X-CN3A pin 4. Repair or replace the wire.

Check for proper resistance in the BRAKE VALVE SOLENOID. Using a multi-meter to check for resistance between BRAKE VALVE SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the BRAKE VALVE SOLENOID has developed an open. Replace the BRAKE VALVE SOLENOID.

C.

If resistance is 0 Ω, the BRAKE VALVE SOLENOID has shorted internally. Replace the BRAKE VALVE SOLENOID.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3A-4 and CN1A-1. A.

If resistance is normal, continue with step 5.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM 84522361 15/06/2011

A.50.A / 181

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 28 (A.30.A.88-C.20.E.28)

84522361 15/06/2011

A.50.A / 182

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4057- Park Brake Valve (On/Off) - Solenoid Supply STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4057 has an error priority of Red. Disable Ground Drive operating mode is enabled with Diagnostic Trouble Code 4057. Cause: The UCM has sent a signal to the Park Brake Valve solenoid to de-energize, but voltage is still active. (The fault is only activated when Hydraulics are Disabled or Park Brake is enabled and Park Brake Valve solenoid output pin voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 4057 - Park Brake Valve (On/Off) Solenoid Supply STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for short to high. Disconnect connector X-BRK from the BRAKE VALVE SOLENOID. Disconnect connector X-CN3A from the UCM. Using a multi-meter, check for voltage between connector X-BRK pin 1, or connector X-CN3A pin 4 and ground. A.

If there is no voltage, continue with step 3.

B.

If there is voltage, there is a short to high source on wire 258 (White) between connector X-BRK pin 1 and connector X-CN3A pin 4. Repair or replace the wire.

Check for proper operation of the UCM. Reconnect connector X-CN3A to the UCM. Using a multi-meter, check for voltage between connector X-BRK pin 1 and ground. A.

If voltage is greater than 8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 8 V, continue with step 4.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 28 (A.30.A.88-C.20.E.28)

84522361 15/06/2011

A.50.A / 183

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4061- Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4061 has an error priority of Red. Disable Forward Ground Drive is enabled with Diagnostic Trouble Code 4061. Cause: UCM has sensed improper RH Drive Pump Forward Solenoid current. (The fault is only activated when Hydraulics are enabled and solenoid currents are incorrect.) Possible failure modes: 1.

RH Drive Pump Forward solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4061 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply OC is present. A.

If the fault is present, continue with step 2.

B.

If the fault is not present, the fault may be intermittent and not currently active, continue with step 6.

Check for open circuit. Disconnect connector X-17 from the RH DRIVE PUMP FORWARD SOLENOID. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check continuity between connector X-17 pin 1 and connector X-CN3B pin 32. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 519 (White) between connector X-17 pin 1 and connector X-CN3B pin 32. Repair or replace the open wire.

Check for proper resistance in the RH DRIVE PUMP FORWARD SOLENOID. Using a multi-meter to check for resistance between RH DRIVE PUMP FORWARD SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the RH DRIVE PUMP FORWARD SOLENOID has developed an open. Replace the RH DRIVE PUMP FORWARD SOLENOID.

C.

If resistance is 0 Ω, the RH DRIVE PUMP FORWARD SOLENOID has shorted internally. Replace the RH DRIVE PUMP FORWARD SOLENOID.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-17 pin 2 and ground. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26 and 27 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-32 and CN1A-1. A.

If resistance is normal, continue with step 6. 84522361 15/06/2011

A.50.A / 184

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 185

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4062- Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4062 has an error priority of Red. Disable Forward Ground Drive is enabled with Diagnostic Trouble Code 4062. Cause: The UCM has sent a signal to the Right Forward Ground Drive Solenoid to energize, but there is no voltage detected. (The fault is only activated when Hydraulics are enabled and Aux Override is disabled and Park Brake is off and solenoid output pin current is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

RH Drive Pump Forward Solenoid has failed.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4062 - Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for a short to ground. Disconnect connector X-17 from the RH DRIVE PUMP FORWARD SOLENOID. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check for continuity between connector X-17 pin 1, or connector X-CN3B pin 32 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 519 (White) between connector X-17 pin 1 and connector X-CN3B pin 32. Repair or replace the wire.

Check for proper resistance in the RH DRIVE PUMP FORWARD SOLENOID. Using a multi-meter to check for resistance between RH DRIVE PUMP FORWARD SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the RH DRIVE PUMP FORWARD SOLENOID has developed an open. Replace the RH DRIVE PUMP FORWARD SOLENOID.

C.

If resistance is 0 Ω, the RH DRIVE PUMP FORWARD SOLENOID has shorted internally. Replace the RH DRIVE PUMP FORWARD SOLENOID.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-32 and CN1A-1. A.

If resistance is normal, continue with step 5.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Inves84522361 15/06/2011

A.50.A / 186

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

tigate nearby wiring. If multiple Diagnostic Trouble Codes are active, troubleshoot another Diagnostic Trouble Code. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 187

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4071- Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4071 has an error priority of Red. Disable Forward Ground Drive is enabled with Diagnostic Trouble Code 4071. Cause: UCM has sensed improper Left Drive Pump Forward Solenoid current. (The fault is only activated when Hydraulics are enabled and solenoid currents are incorrect.) Possible failure modes: 1.

Left Drive Pump Forward solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4071 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for open circuit. Disconnect connector X-13 from the LEFT DRIVE PUMP FORWARD SOLENOID. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check continuity between connector X-13 pin 1 and connector X-CN3B pin 33. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 516 (White) between connector X-13 pin 1 and connector X-CN3B pin 33. Repair or replace the wire.

Check for proper resistance in the LEFT DRIVE PUMP FORWARD SOLENOID. Using a multi-meter to check for resistance between LEFT DRIVE PUMP FORWARD SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the LEFT DRIVE PUMP FORWARD SOLENOID has developed an open. Replace the LEFT DRIVE PUMP FORWARD SOLENOID.

C.

If resistance is 0 Ω, the LEFT DRIVE PUMP FORWARD SOLENOID has shorted internally. Replace the LEFT DRIVE PUMP FORWARD SOLENOID.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-13 pin 2 and ground. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26 and 27 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-33 and CN1A-1. A.

If resistance is normal, continue with step 6. 84522361 15/06/2011

A.50.A / 188

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 189

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4072- Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4072 has an error priority of Red. Disable Forward Ground Drive is enabled with Diagnostic Trouble Code 4072. Cause: The UCM has sent a signal to the Left Drive Pump Forward Solenoid to energize, but there is no voltage detected. (The fault is only activated when Hydraulics are enabled and Aux Override is disabled and Parking Brake is off and solenoid output pin current is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Left Drive Pump Forward Solenoid has failed.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4072 - Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for a short to ground. Disconnect connector X-13 from the LEFT DRIVE PUMP FORWARD SOLENOID. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check for continuity between connector X-13 pin 1, or connector X-CN3B pin 33 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 516 (White) between connector X-13 pin 1 and connector X-CN3B pin 33. Repair or replace the shorted wire.

Check for proper resistance in the LEFT DRIVE PUMP FORWARD SOLENOID. Using a multi-meter to check for resistance between LEFT DRIVE PUMP FORWARD SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the LEFT DRIVE PUMP FORWARD SOLENOID has developed an open. Replace the LEFT DRIVE PUMP FORWARD SOLENOID.

C.

If resistance is 0 Ω, the LEFT DRIVE PUMP FORWARD SOLENOID has shorted internally. Replace the LEFT DRIVE PUMP FORWARD SOLENOID.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-33 and CN1A-1. A.

If resistance is normal, continue with step 5.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent

84522361 15/06/2011

A.50.A / 190

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 191

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4081- Forward Pump Control Valves (Directional) - Common Solenoid Return STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4081 has an error priority of Red. Disable Forward Ground Drive is enabled with Diagnostic Trouble Code 4081. Cause: UCM has sensed higher than normal voltage on the Forward Ground Drive Valve Solenoids ground line. (The fault is only activated when Hydraulics are disabled and solenoid voltage feedback is greater than 5 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4081 - Forward Pump Control Valves (Directional) - Common Solenoid Return STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high. Disconnect connector X-CN2B from the UCM. Disconnect connector X-CN3B from the UCM. Disconnect connector X-13 from the LEFT HAND DRIVE PUMP FORWARD. Disconnect connector X-17 from the RIGHT HAND DRIVE PUMP FORWARD. Using a multi-meter, check for voltage between connector X-17 pin 1 and ground. A.

If there is no voltage, continue with step 3.

B.

If there is voltage, there is a short to high source on wire 519 (White) between connector X-17 pin 1 and connector X-CN3B pin 32. Repair or replace the wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-17 pin 2 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 1021/1040 (Blue) between connector X-CN2B pin 25 and connector X-17 pin 2, or on wire 1038 (Blue) between SPLICE 098 and connector X-13 pin 2. Repair or replace the wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-13 pin 1 and ground. A.

If there is no voltage, continue with step 5.

B.

If there is voltage, there is a short to high source on wire 516 (White) between connector X-CN3B pin 33 and connector X-13 pin 1. Repair or replace the wire.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement.

84522361 15/06/2011

A.50.A / 192

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 193

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4082- Forward Pump Control Valves (Directional) - Pumps Forward Solenoids STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4082 has an error priority of Red. Disable Forward Ground Drive is enabled with Diagnostic Trouble Code 4082. Cause: UCM has sensed that the solenoid return voltage is low. (The fault is only activated when Hydraulics are disabled and solenoid return voltage feedback is low.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of UCM.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 4082 - Forward Pump Control Valves (Directional) - Pumps Forward Solenoids STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for a short to ground. Disconnect connector X-17 from the RH DRIVE PUMP FORWARD. Disconnect connector X-13 from the LEFT DRIVE PUMP FORWARD. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check for continuity between connector X-17 pin 2 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 1021/1040 (Blue) between connector X-CN1A pin 13 and connector X-17 pin 2, or on wire 1038 (Blue) between SPLICE 098 and connector X-13 pin 2. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2B-25 and CN1A-1. A.

If resistance is normal, continue with step 4.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

84522361 15/06/2011

A.50.A / 194

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 195

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4083- Forward Pump Control Valves (Directional) - Common Solenoid Return OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4083 has an error priority of Red. Disable Forward Ground Drive operating mode is enabled with Diagnostic Trouble Code 4083. Cause: UCM has sensed improper Forward Pump Control Valve solenoid current. (The fault is only activated when Hydraulics are enabled and solenoid return current is incorrect.) Possible failure modes: 1.

Open wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 4083 - Forward Pump Control Valves (Directional) - Common Solenoid Return OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for an open wire condition. Disconnect connector X-CN2B from the UCM. Disconnect connector X-17 from the RH DRIVE PUMP FORWARD SOLENOID. Disconnect connector X-13 from the LEFT DRIVE PUMP FORWARD SOLENOID. Using a multi-meter, check for continuity between X-CN2B pin 25 and X-13 pin 2. A.

If there is no continuity, there is an open wire condition on wire 1021 (Blue) X-CN2B pin 25 and SPLICE 098. Repair or replace the wire.

B.

If there is continuity, continue with step 3.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2B-25 and CN1A-1. A.

If resistance is normal, continue with step 4.

B.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) 84522361 15/06/2011

A.50.A / 196

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4309- Park Brake Button - Park Brake Button Timeout (30 sec) L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4309 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. There are no restrictions with Diagnostic Trouble Code 4309. Cause: UCM has sensed that the signal has failed. (The fault is only activated when Ignition is On and Park Brake button output is high for more than 30 s.) Possible failure modes: 1.

Failure of Park Brake switch.

2.

Failure of UCM.

3.

Failure of Instrument Cluster.

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 4309 - Park Brake Button - Park Brake Button Timeout (30 sec) is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check for proper resistance in the NH PARK BRAKE SWITCH. Disconnect connector X-365 from the NH PARK BRAKE SWITCH. Using a multi-meter, check for resistance between NH PARK BRAKE SWITCH pins 2 and 3. A.

If resistance is infinite, the NH PARK BRAKE SWITCH is not closed. Continue with step 3.

B.

If resistance is 0 Ω, the NH PARK BRAKE SWITCH has shorted internally. Replace the NH PARK BRAKE SWITCH.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 06 (A.30.A.88-C.20.E.06)

84522361 15/06/2011

A.50.A / 197

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4361-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4361 has an error priority of Red. Disable Reverse Ground Drive operating mode is enabled with Diagnostic Trouble Code 4361. Cause: UCM has sensed improper Right Reverse Ground Drive Solenoid current. (The fault is only activated when Hydraulics are enabled and solenoid currents are incorrect.) Possible failure modes: 1.

Right Reverse Ground Drive solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4361 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for open circuit. Disconnect connector X-18 from the RIGHT DRIVE PUMP REVERSE SOLENOID. Disconnect connector X-CN2A from the UCM. Using a multi-meter, check continuity between connector X-18 pin 1 and connector X-CN2A pin 8. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 518 (White) between connector X-18 pin 1 and connector X-CN2A pin 8. Repair or replace the wire.

Check for proper resistance in the RIGHT DRIVE PUMP REVERSE SOLENOID. Using a multi-meter to check for resistance between RIGHT DRIVE PUMP REVERSE SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the RIGHT DRIVE PUMP REVERSE SOLENOID has developed an open. Replace the RIGHT DRIVE PUMP REVERSE SOLENOID.

C.

If resistance is 0 Ω, the RIGHT DRIVE PUMP REVERSE SOLENOID has shorted internally. Replace the RIGHT DRIVE PUMP REVERSE SOLENOID.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-18 pin 2 and ground. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26 and 27 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2A-8 and CN1A-1. A.

If resistance is normal, continue with step 6. 84522361 15/06/2011

A.50.A / 198

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 199

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4362- Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4362 has an error priority of Red. Disable Reverse Ground Drive operating mode is enabled with Diagnostic Trouble Code 4362. Cause: The UCM has sent a signal to the Right Reverse Ground Drive Solenoid to energize, but there is no voltage detected. (The fault is only activated when Hydraulics are enabled and Aux Override is disabled and Park Brake is off and solenoid output pin current is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Right Reverse Ground Drive Solenoid has failed.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4362 - Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for a short to ground. Disconnect connector X-18 from the RIGHT DRIVE PUMP REVERSE SOLENOID. Disconnect connector X-CN2A from the UCM. Using a multi-meter, check for continuity between connector X-18 pin 1, or connector X-CN2A pin 8 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 518 (White) between connector X-18 pin 1 and connector X-CN2A pin 8. Repair or replace the wire.

Check for proper resistance in the RIGHT DRIVE PUMP REVERSE SOLENOID. Using a multi-meter to check for resistance between RIGHT DRIVE PUMP REVERSE SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the RIGHT DRIVE PUMP REVERSE SOLENOID has developed an open. Replace the RIGHT DRIVE PUMP REVERSE SOLENOID.

C.

If resistance is 0 Ω, the RIGHT DRIVE PUMP REVERSE SOLENOID has shorted internally. Replace the RIGHT DRIVE PUMP REVERSE SOLENOID.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2A-8 and CN1A-1. A.

If resistance is normal, continue with step 5.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Inves84522361 15/06/2011

A.50.A / 200

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

tigate nearby wiring. If multiple Diagnostic Trouble Codes are active, troubleshoot another Diagnostic Trouble Code. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 201

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4371- Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4371 has an error priority of Red. Disable Reverse Ground Drive operating mode is enabled with Diagnostic Trouble Code 4371. Cause: UCM has sensed improper Left Reverse Ground Drive solenoid current. (The fault is only activated when Hydraulics are enabled and solenoid supply current is incorrect.) Possible failure modes: 1.

Left Drive Pump Reverse solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4371 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for open circuit. Disconnect connector X-16 from the LEFT DRIVE PUMP REVERSE SOLENOID. Disconnect connector X-CN2A from the UCM. Using a multi-meter, check continuity between connector X-16 pin 1 and connector X-CN2A pin 14. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 517 (White) between connector X-16 pin 1 and connector X-CN2A pin 14. Repair or replace the wire.

Check for proper resistance in the LEFT DRIVE PUMP REVERSE SOLENOID. Using a multi-meter to check for resistance between LEFT DRIVE PUMP REVERSE SOLENOID pins 1 and 2 A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the LEFT DRIVE PUMP REVERSE SOLENOID has developed an open. Replace the LEFT DRIVE PUMP REVERSE SOLENOID.

C.

If resistance is 0 Ω, the LEFT DRIVE PUMP REVERSE SOLENOID has shorted internally. Replace the LEFT DRIVE PUMP REVERSE SOLENOID.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-16 pin 2 and ground. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26 and 27 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2A-14 and CN1A-1. A.

If resistance is normal, continue with step 6. 84522361 15/06/2011

A.50.A / 202

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 203

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4372- Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4372 has an error priority of Red. Disable Reverse Ground Drive operating mode is enabled with Diagnostic Trouble Code 4372. Cause: The UCM has sent a signal to the Left Reverse Ground Drive Solenoid to energize, but there is no voltage detected. (The fault is only activated when Hydraulics are enabled and Aux Override is disabled and Loader Lock is off and solenoid output pin current is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Left Reverse Ground Drive Solenoid has failed.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4372 - Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for a short to ground. Disconnect connector X-16 from the LEFT DRIVE PUMP REVERSE SOLENOID. Disconnect connector X-CN2A from the UCM. Using a multi-meter, check for continuity between connector X-16 pin 1, or connector X-CN2A pin 14 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 517 (White) between connector X-16 pin 1 and connector X-CN2A pin 14. Repair or replace wire.

Check for proper resistance in the LEFT DRIVE PUMP REVERSE SOLENOID. Using a multi-meter to check for resistance between LEFT DRIVE PUMP REVERSE SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the LEFT DRIVE PUMP REVERSE SOLENOID has developed an open. Replace the LEFT DRIVE PUMP REVERSE SOLENOID.

C.

If resistance is 0 Ω, the LEFT DRIVE PUMP REVERSE SOLENOID has shorted internally. Replace the LEFT DRIVE PUMP REVERSE SOLENOID.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2A-14 and CN1A-1. A.

If resistance is normal, continue with step 5.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Inves84522361 15/06/2011

A.50.A / 204

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

tigate nearby wiring. If multiple Diagnostic Trouble Codes are active, troubleshoot another Diagnostic Trouble Code. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 205

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4381- Reverse Pump Control Valves (Directional) - Common Solenoid Return STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4381 has an error priority of Red. Disable Reverse Ground Drive operating mode is enabled with Diagnostic Trouble Code 4381. Cause: UCM has sensed higher than normal voltage on the Reverse Ground Drive Valve Solenoids ground line. (The fault is only activated when Hydraulics are disabled and solenoid voltage is greater than 5 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4381 - Reverse Pump Control Valves (Directional) - Common Solenoid Return STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high. Disconnect connector X-CN1A from the UCM. Disconnect connector X-CN2A from the UCM. Disconnect connector X-16 from the LEFT DRIVE PUMP REVERSE. Disconnect connector X-18 from the RIGHT DRIVE PUMP REVERSE. Using a multi-meter, check for voltage between connector X-18 pin 1 and ground. A.

If there is no voltage, continue with step 3.

B.

If there is voltage, there is a short to high source on wire 518 (White) between connector X-18 pin 1 and connector X-CN2A pin 8. Repair or replace the wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-18 pin 2 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 1022/1041 (Blue) between connector X-CN1A pin 19 and connector X-18 pin 2, or on wire 1039 (Blue) between SPLICE 099 and connector X-16 pin 2. Repair or replace the wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-16 pin 1 and ground. A.

If there is no voltage, continue with step 5.

B.

If there is voltage, there is a short to high source on wire 517 (White) between connector X-CN2A pin 14 and connector X-16 pin 1. Repair or replace the wire.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement.

84522361 15/06/2011

A.50.A / 206

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 207

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4382- Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4382 has an error priority of Red. Disable Reverse Ground Drive is enabled with Diagnostic Trouble Code 4382. Cause: UCM has sensed that the solenoid return voltage is low. (The fault is only activated when Hydraulics are disabled and solenoid return voltage feedback is low.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of UCM.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 4382 - Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for a short to ground. Disconnect connector X-18 from the RIGHT DRIVE PUMP REVERSE. Disconnect connector X-16 from the LEFT DRIVE PUMP REVERSE. Disconnect connector X-CN1A from the UCM. Using a multi-meter, check for continuity between connector X-18 pin 2 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 1022/1041 (Blue) between connector X-CN1A pin 13 and connector X-18 pin 2, or on wire 1039 (Blue) between SPLICE 099 and connector X-16 pin 2. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1A-19 and CN1A-1. A.

If resistance is normal, continue with step 4.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

84522361 15/06/2011

A.50.A / 208

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 209

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4383- Reverse Pump Control Valves (Directional) - Common Solenoid Return OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4383 has an error priority of Red. Disable Reverse Ground Drive operating mode is enabled with Diagnostic Trouble Code 4383. Cause: UCM has sensed improper Reverse Pump Control Valve solenoid current. (The fault is only activated when Hydraulics are enabled and solenoid return current is incorrect.) Possible failure modes: 1.

Open wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4383 - Reverse Pump Control Valves (Directional) - Common Solenoid Return OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for an open wire condition. Disconnect connector X-CN1A from the UCM. Disconnect connector X-16 from the LEFT DRIVE PUMP REVERSE SOLENOID. Using a multi-meter, check for continuity between X-CN1A pin 19 and X-16 pin 2. A.

If there is no continuity, there is an open wire condition on wire 1022/1039 (Blue) X-CN1A pin 19 and connector X-16 pin 2. Repair or replace the wire.

B.

If there is continuity, continue with step 3.

Check for an open wire condition. Disconnect connector X-18 from the LEFT DRIVE PUMP REVERSE SOLENOID. Using a multi-meter, check for continuity between X-CN1A pin 19 and X-18 pin 2. A.

If there is no continuity, there is an open wire condition on wire 1041 (Blue) between SPLICE 099 and connector X-18 pin 2. Repair or replace the wire.

B.

If there is continuity, continue with step 4.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1A-19 and CN1A-1. A.

If resistance is normal, continue with step 5.

B.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement.

84522361 15/06/2011

A.50.A / 210

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 211

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4431- Park Brake Pressure Switch - Pressure Switch (plausibility check with solenoid valve) L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4431 has an error priority of Hydraulic-Amber. There are no restrictions with Diagnostic Trouble Code 4431. Cause: UCM has sensed disagreement between the PARK BRAKE PRESSURE SWITCH and the PARK BRAKE SOLENOID. (The fault is only activated when Engine is On and PARK BRAKE PRESSURE SWITCH input and PARK BRAKE SOLENOID output are not the same.) Possible failure modes: 1.

Failure of PARK BRAKE PRESSURE SWITCH.

2.

Failure of PARK BRAKE SOLENOID.

3.

Failure of UCM.

4.

Open or shorted wire in circuit.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 4431 - Park Brake Pressure Switch Pressure Switch (plausibility check with solenoid valve) is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 9.

Check if Diagnostic Trouble Code 4055, 4056, or 4057 is active. A.

If any of these Diagnostic Trouble Codes are active, follow the resolution procedure for these codes first.4055- Park Brake Valve (On/Off) - Solenoid Supply OC (D.32.C) 4056- Park Brake Valve (On/Off) - Solenoid Supply STG (D.32.C) 4057- Park Brake Valve (On/Off) - Solenoid Supply STP (D.32.C) When these Diagnostic Trouble Codes are no longer active, continue with this procedure.

B.

If none of these Diagnostic Trouble Codes are active, continue with step 3.

Check for open circuit. Disconnect connector X-BRKPRS from the BRAKE PRESSURE SWITCH. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check continuity between connector X-BRKPRS pin 1 and connector X-CN2B pin 13. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 535 (Yellow) between connector X-BRKPRS pin 1 and connector X-CN2B pin 13. Repair or replace the open wire.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-BRKPRS pin 2 and ground. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 28 and 1 to troubleshoot and isolate the faulty wire.

84522361 15/06/2011

A.50.A / 212

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5.

6.

7.

8.

9.

Check for a short to ground. Disconnect connector X-BRKPRS from the BRAKE PRESSURE SWITCH. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check for continuity between connector X-BRKPRS pin 1, or connector X-CN2B pin 13 and ground. A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 535 (Yellow) between connector X-BRKPRS pin 1 and connector X-CN2B pin 13. Repair or replace the shorted wire.

Check for short to high. Disconnect connector X-BRKPRS from the BRAKE PRESSURE SWITCH. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check for voltage between connector X-BRKPRS pin 1, or connector X-CN2B pin 13 and ground. A.

If there is no voltage, continue with step 7.

B.

If there is voltage, there is a short to high source on wire 535 (Yellow) between connector X-BRKPRS pin 1 and connector X-CN2B pin 13. Repair or replace the shorted wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2B-13 and CN1A-1. A.

If resistance is around 4500 Ω, continue with step 8.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 10 K Ω, the UCM has opened internally. Replace the UCM.

Cycle the BRAKE PRESSURE SWITCH and monitor the EST and INSTRUMENT CLUSTER. Check to see if Diagnostic Trouble Code 4431 - Park Brake Pressure Switch - Pressure Switch (plausibility check with solenoid valve) clears. A.

If the Diagnostic Trouble Code clears, continue with step 9.

B.

If the Diagnostic Trouble Code does not clear, the BRAKE PRESSURE SWITCH has failed. Replace the BRAKE PRESSURE SWITCH.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 28 (A.30.A.88-C.20.E.28) Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 213

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4731- Right Swashplate angle sensor - Pin A STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4731 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 4731. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Engine is On and Right Swashplate angle sensor Voltage is less than 0.2 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Swashplate Angle Sensor.

3.

Open wire in circuit.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4731 - Right Swashplate angle sensor - Pin A STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for open circuit. Disconnect connector X-93 from RH PUMP SWASH PLATE SENSOR. Disconnect connector X-CN2B from UCM. Using a multi-meter, check continuity between connector X-93 pin 4 and connector X-CN2B pin 32. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 576 (Yellow) between connector X-93 pin 4 and connector X-CN2B pin 32. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-CN2B pin 32, or connector X-93 pin 4 and chassis ground. A.

If there is no continuity, continue with 4.

B.

If there is continuity, there is a short to ground condition on wire 576 (Yellow) between connector X-CN2B pin 32 and connector X-93 pin 4. Repair or replace the shorted wire.

Check for proper resistance in the RH PUMP SWASH PLATE SENSOR by using a multi-meter to check for resistance between RH PUMP SWASH PLATE SENSOR pins 4 and 6. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the RH PUMP SWASH PLATE SENSOR has developed an open, replace the RH PUMP SWASH PLATE SENSOR.

C.

If resistance is 0 Ω, the RH PUMP SWASH PLATE SENSOR has shorted internally. Reeplace the RH PUMP SWASH PLATE SENSOR.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-93 pin 6 and ground. A.

If there is continuity, continue with step 6. 84522361 15/06/2011

A.50.A / 214

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

If there is no continuity, there is and open in the ground circuit. Use Frames 1 and 27 to troubleshoot and isolate the faulty wire.

Check for a short in the UCM. Completely power down the UCM by removing all six connectors. Using a multimeter, check for resistance between UCM pins CN2B-32 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 215

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4732- Right Swashplate angle sensor - Pin A STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4732 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 4732. Cause: UCM has sensed higher than normal voltage on pin A of the RH Pump Swash Plate Sensor. (The fault is only activated when Ignition is On and RH Pump Swash Plate Sensor voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of RH Pump Swash Plate Sensor.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4732 - Right Swashplate angle sensor - Pin A STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high source. Disconnect connector X-93 from RH PUMP SWASH PLATE SENSOR. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check voltage between connector X-93 pin 4, or X-CN2B pin 32 and battery ground. A.

If there is voltage, there is a short to high source on wire 576 (Yellow). Repair or replace wire.

B.

If there is no voltage, continue with step 3.

Check for proper operation of the RH PUMP SWASH PLATE SENSOR. Reconnect connector X-93 to the RH PUMP SWASH PLATE SENSOR. Using a multi-meter, check voltage between connector X-CN2B pin 32 and ground. A.

If voltage greater than 4.8 V, the RH PUMP SWASH PLATE SENSOR has failed. Replace the RH PUMP SWASH PLATE SENSOR.

B.

If voltage is less than 4.8 V, continue with step 4.

Check for proper operation of the UCM. Disconnect connector X-93 from the RH PUMP SWASH PLATE SENSOR. Reconnect connector X-CN2B to the UCM. Using a multi-meter, check voltage between connector X-93 pin 4 and ground. A.

If voltage greater than 4.8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 4.8 V, continue with step 5.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 84522361 15/06/2011

A.50.A / 216

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27)

84522361 15/06/2011

A.50.A / 217

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4734- Right Swashplate angle sensor - Pin B STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4734 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 4734. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Engine is On and Right Swashplate angle sensor voltage is less than 0.2 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Swashplate Angle Sensor.

3.

Open wire in circuit.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4734 - Right Swashplate angle sensor - Pin B STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for open circuit. Disconnect connector X-93 from RH PUMP SWASH PLATE SENSOR. Disconnect connector X-CN2B from UCM. Using a multi-meter, check continuity between connector X-93 pin 3 and connector X-CN2B pin 33. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 575 (Yellow) between connector X-93 pin 3 and connector X-CN2B pin 33. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-CN2B pin 33, or connector X-93 pin 3 and chassis ground. A.

If there is no continuity, continue with 4.

B.

If there is continuity, there is a short to ground condition on wire 575 (Yellow) between connector X-CN2B, pin 33 and connector X-93 pin 3. Repair or replace the open wire.

Check for proper resistance in the RH PUMP SWASH PLATE SENSOR by using a multi-meter to check for resistance between RH PUMP SWASH PLATE SENSOR pins 3 and 1. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the RH PUMP SWASH PLATE SENSOR has developed an open, replace the RH PUMP SWASH PLATE SENSOR.

C.

If resistance is 0 Ω, the RH PUMP SWASH PLATE SENSOR has shorted internally. Replace the RH PUMP SWASH PLATE SENSOR.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-93 pin 1 and ground. A.

If there is continuity, continue with step 6. 84522361 15/06/2011

A.50.A / 218

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

If there is no continuity, there is and open in the ground circuit, use Frames 1 and 27 to troubleshoot and isolate the faulty wire.

Check for a short in the UCM. Completely power down the UCM by removing all six connectors. Using a multimeter, check for resistance between UCM pins CN2B-33 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 219

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4735- Right Swashplate angle sensor - Pin B STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4735 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 4735. Cause: UCM has sensed higher than normal voltage on pin B of the RH Pump Swash Plate Sensor. (The fault is only activated when Ignition is On and RH Pump Swash Plate Sensor voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of RH Pump Swash Plate Sensor.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4735 - Right Swashplate angle sensor - Pin B STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high source. Disconnect connector X-93 from RH PUMP SWASH PLATE SENSOR. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check voltage between connector X-93 pin 3, or connector X-CN2B pin 33 and ground. A.

If there is voltage, there is a short to voltage condition on wire 575 (Yellow) between connector X-93 pin 3 and connector X-CN2B pin 33. Repair or replace the shorted wire.

B.

If there is no voltage, continue with step 3.

Check for source of higher than normal voltage. Reconnect connector X-93 to the RH PUMP SWASH PLATE SENSOR. Using a multi-meter, check voltage between connector X-CN2B pin 33 and ground. A.

If voltage greater than 4.8 V the RH PUMP SWASH PLATE SENSOR has failed. Replace the RH PUMP SWASH PLATE SENSOR.

B.

If there is less than 4.8 V, continue with step 4.

Check for source of higher than normal voltage. Disconnect connector X-93 from RH PUMP SWASH PLATE SENSOR. Reconnect connector X-CN2B to the UCM. Using a multi-meter, check voltage between connector X-93 pin 3 and ground. A.

If voltage greater than 4.8 V the UCM has an internal fault. Replace the UCM.

B.

If there is less than 4.8 V, continue with step 5.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 84522361 15/06/2011

A.50.A / 220

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27)

84522361 15/06/2011

A.50.A / 221

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4737- Right Swashplate angle sensor - in-range fault L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4737 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 4737. Cause: UCM has sensed that the RIGHT SWASHPLATE ANGLE SENSOR has failed. (The fault is only activated when Engine is On and the sum of the Right Swashplate Angle Sensor output voltages falls out of the range of 4.8 V to 5.2 V.) Possible failure modes: 1.

Failure of the RIGHT SWASHPLATE ANGLE SENSOR

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 4737 - Right Swashplate angle sensor - in-range fault is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check Instrument Cluster for other Trouble Codes. A.

If the other Trouble Codes are active, follow the procedure for those first.

B.

If the no other Trouble Codes are active, the RIGHT SWASHPLATE ANGLE SENSOR has failed. Replace the RIGHT SWASHPLATE ANGLE SENSOR.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27)

84522361 15/06/2011

A.50.A / 222

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4741- Left Swashplate angle sensor - Pin A STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4741 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 4741. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Engine is On and Left Swashplate angle sensor Voltage is less than 0.2 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Swashplate Angle Sensor.

3.

Open wire in circuit.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4741 - Left Swashplate angle sensor - Pin A STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for open circuit. Disconnect connector X-94 from LH PUMP SWASH PLATE SENSOR. Disconnect connector X-CN3A from UCM. Using a multi-meter, check continuity between connector X-94 pin 3 and connector X-CN3A pin 9. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 574 (Yellow) between connector X-94 pin 3 and connector X-CN3A pin 9. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-CN3A pin 9, or connector X-94 pin 3 and chassis ground. A.

If there is no continuity, continue with step 4.

B.

If there is continuity, there is a short to ground condition on wire 574 (Yellow) between connector X-CN3A pin 9 and connector X-94 pin 3. Repair or replace the shorted wire.

Check for proper resistance in the LH PUMP SWASH PLATE SENSOR by using a multi-meter to check for resistance between LH PUMP SWASH PLATE SENSOR pins 3 and 1. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the LH PUMP SWASH PLATE SENSOR has developed an open, replace the LH PUMP SWASH PLATE SENSOR.

C.

If resistance is 0 Ω, the LH PUMP SWASH PLATE SENSOR has shorted internally. Replace the LH PUMP SWASH PLATE SENSOR.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-94 pin 3 and ground. A.

If there is continuity, continue with step 6. 84522361 15/06/2011

A.50.A / 223

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

If there is no continuity, there is and open in the ground circuit. Use Frames 1 and 27 to troubleshoot and isolate the faulty wire.

Check for a short in the UCM. Completely power down the UCM by removing all six connectors. Using a multimeter, check for resistance between UCM pins CN3A-9 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 224

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4742- Left Swashplate angle sensor - Pin A STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4742 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 4742. Cause: UCM has sensed higher than normal voltage on pin A of the LH Pump Swash Plate Sensor. (The fault is only activated when Ignition is On and LH Pump Swash Plate Sensor voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of LH Pump Swash Plate Sensor.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4742 - Left Swashplate angle sensor - Pin A STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high source. Disconnect connector X-94 from LH PUMP SWASH PLATE SENSOR. Disconnect connector X-CN3A from UCM. Using a multi-meter, check voltage between connector X-94 pin 3, or connector X-CN3A pin 9 and ground. A.

If there is voltage, there is a short to voltage condition on wire 574 (Yellow) between connector X-94 pin 3 and connector X-CN3A pin 9. Repair or replace the shorted wire.

B.

If there is no voltage, continue with step 3.

Check for source of higher than normal voltage. Reconnect connector X-94 to the LH PUMP SWASH PLATE SENSOR. Using a multi-meter, check voltage between connector X-CN3A pin 9 and ground. A.

If voltage greater than 4.8 V, the LH PUMP SWASH PLATE SENSOR has failed. Replace the LH PUMP SWASH PLATE SENSOR.

B.

If there is less than 4.8 V, continue with step 4.

Check for source of higher than normal voltage. Disconnect connector X-94 from the LH PUMP SWASH PLATE SENSOR Reconnect connector X-CN3A to the UCM. Using a multi-meter, check voltage between connector X-94 pin 3 and ground. A.

If voltage greater than 4.8 V the UCM has an internal fault. Replace the UCM.

B.

If there is less than 4.8 V, continue with step 5.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 84522361 15/06/2011

A.50.A / 225

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27)

84522361 15/06/2011

A.50.A / 226

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4744- Left Swashplate angle sensor - Pin B STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4744 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 4744. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Engine is On and Left Swashplate angle sensor Voltage is less than 0.2 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Swashplate Angle Sensor.

3.

Open wire in circuit.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4744 - Left Swashplate angle sensor - Pin B STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for open circuit. Disconnect connector X-94 from LH PUMP SWASH PLATE SENSOR. Disconnect connector X-CN3A from UCM. Using a multi-meter, check continuity between connector X-94 pin 4 and connector X-CN3A pin 10. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 573 (Yellow) between connector X-94 pin 4 and connector X-CN3A pin 10. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-CN3A pin 10, or connector X-94 pin 4 and chassis ground. A.

If there is no continuity, continue with 4.

B.

If there is continuity, there is a short to ground condition on wire 573 (Yellow) between connector X-CN3A, pin 10 and connector X-94 pin 4. Repair or replace the shorted wire.

Check for proper resistance in the LH PUMP SWASH PLATE SENSOR by using a multi-meter to check for resistance between LH PUMP SWASH PLATE SENSOR pins 4 and 6. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the LH PUMP SWASH PLATE SENSOR has developed an open. Replace the LH PUMP SWASH PLATE SENSOR.

C.

If resistance is 0 Ω, the LH PUMP SWASH PLATE SENSOR has shorted internally. Replace the LH PUMP SWASH PLATE SENSOR.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-94 pin 6 and ground. A.

If there is continuity, continue with step 6. 84522361 15/06/2011

A.50.A / 227

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

If there is no continuity, there is an open in the ground circuit. Use Frames 1 and 27 to troubleshoot and isolate the faulty wire.

Check for a short in the UCM. Completely power down the UCM by removing all six connectors. Using a multimeter, check for resistance between UCM pins CN3A-10 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 228

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4745- Left Swashplate angle sensor - Pin B STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4745 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 4745. Cause: UCM has sensed higher than normal voltage on pin B of the Left Swashplate Angle Sensor. (The fault is only activated when Ignition is On and Left Swashplate Angle Sensor voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Left Swashplate Angle Sensor.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4745 - Left Swashplate angle sensor - Pin B STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high source. Disconnect connector X-94 from LH PUMP SWASH PLATE SENSOR. Disconnect connector X-CN3A from UCM. Using a multi-meter, check voltage between connector X-94 pin 4, or connector X-CN3A pin 10 and ground. A.

If there is voltage, there is a short to voltage condition on wire 573 (Yellow) between connector X-94 pin 4 and connector 25727062 pin 10. Repair or replace the shorted wire.

B.

If there is no voltage, continue with step 3.

Check for source of higher than normal voltage. Reconnect connector X-94 to the LH PUMP SWASH PLATE SENSOR. Using a multi-meter, check voltage between connector X-CN3A pin 10 and ground. A.

If voltage greater than 4.8 V, the LH PUMP SWASH PLATE SENSOR has failed. Replace the LH PUMP SWASH PLATE SENSOR.

B.

If voltage is less than 4.8 V, continue with step 4.

Check for source of higher than normal voltage. Disconnect connector X-94 from the LH PUMP SWASH PLATE SENSOR. Reconnect connector X-CN3A to the UCM. Using a multi-meter, check voltage between connector X-94 pin 4 and ground. A.

If voltage greater than 4.8 V the UCM has an internal fault. Replace the UCM.

B.

If there is less than 4.8 V, continue with step 5.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 84522361 15/06/2011

A.50.A / 229

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27)

84522361 15/06/2011

A.50.A / 230

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4747- Left Swashplate angle sensor - in-range fault L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4747 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 4747. Cause: UCM has sensed that the LEFT SWASHPLATE ANGLE SENSOR has failed. (The fault is only activated when Engine is On and the sum of the Left Swashplate Angle Sensor output voltages falls out of the range of 4.8 V to 5.2 V.) Possible failure modes: 1.

Failure of the LEFT SWASHPLATE ANGLE SENSOR

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 4747 - Left Swashplate angle sensor - in-range fault is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check Instrument Cluster for other Trouble Codes. A.

If the other Trouble Codes are active, follow the procedure for those first.

B.

If the no other Trouble Codes are active, the LEFT SWASHPLATE ANGLE SENSOR has failed. Replace the LEFT SWASHPLATE ANGLE SENSOR.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27)

84522361 15/06/2011

A.50.A / 231

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4752- Left Swashplate angle sensor - Implausible command, command does not match with swashplate angle L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4752 has an error priority of Red. Ground Drive operating mode is disabled with Diagnostic Trouble Code 4752. Cause: UCM has sensed that the Left Swashplate Angle Sensor does not agree with the direction of vehicle travel. (The fault is only activated when Engine is On and the Left Swashplate Angle Sensor senses vehicle movement when the solenoids are not energized or vehicle movement opposite of the energized solenoid.) Possible failure modes: 1.

Improper wiring in circuit.

2.

Failure of LH PUMP SWASH PLATE SENSOR.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4752 - Left Swashplate angle sensor - Implausible command, command does not match with swashplate angle is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for proper connections to the RIGHT DRIVE PUMP REVERSE, LEFT DRIVE PUMP REVERSE, RH DRIVE PUMP FORWARD, and LEFT DRIVE PUMP FORWARD solenoids. Ensure that connector X-18 is connected to the RIGHT DRIVE PUMP REVERSE solenoid. Ensure that connector X-16 is connected to the LEFT DRIVE PUMP REVERSE solenoid. Ensure that connector X-17 is connected to the RH DRIVE PUMP FORWARD solenoid. Ensure that connector X-13 is connected to the LEFT DRIVE PUMP FORWARD solenoid. A.

If all connectors are correctly installed, continue with step 3.

B.

If any connector is not correctly installed, Use frame 27 to ensure connectors X-18, X-16, X-17, and X-13 are installed correctly.

Check for proper connections to LH PUMP SWASH PLATE SENSOR and RH PUMP SWASH PLATE SENSOR. Ensure that connector X-94 is connected to the LH PUMP SWASH PLATE SENSOR. Ensure that connector X-93 is connected to the RH PUMP SWASH PLATE SENSOR. A.

If both connectors are correctly installed, continue with step 4.

B.

If either connector is not correctly installed, Use frame 27 to ensure connectors X-94 and X-93 are installed correctly.

Check Instrument Cluster for other Trouble Codes. A.

If the other Trouble Codes are active, follow the procedure for those first.

B.

If the no other Trouble Codes are active, the LH PUMP SWASH PLATE SENSOR has failed. Replace the LH PUMP SWASH PLATE SENSOR.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. 84522361 15/06/2011

A.50.A / 232

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27)

84522361 15/06/2011

A.50.A / 233

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4754- Right Swashplate angle sensor - Implausible command, command does not match with swashplate angle L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4754 has an error priority of Red. Ground Drive operating mode is disabled with Diagnostic Trouble Code 4754. Cause: UCM has sensed that the Right Swashplate Angle Sensor does not agree with the direction of vehicle travel. (The fault is only activated when Engine is On and the Right Swashplate Angle Sensor senses vehicle movement when the solenoids are not energized or vehicle movement opposite of the energized solenoid.) Possible failure modes: 1.

Improper wiring in circuit.

2.

Failure of RH PUMP SWASH PLATE SENSOR.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4754 - Right Swashplate angle sensor - Implausible command, command does not match with swashplate angle is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for proper connections to the RIGHT DRIVE PUMP REVERSE, LEFT DRIVE PUMP REVERSE, RH DRIVE PUMP FORWARD, and LEFT DRIVE PUMP FORWARD solenoids. Ensure that connector X-18 is connected to the RIGHT DRIVE PUMP REVERSE solenoid. Ensure that connector X-16 is connected to the LEFT DRIVE PUMP REVERSE solenoid. Ensure that connector X-17 is connected to the RH DRIVE PUMP FORWARD solenoid. Ensure that connector X-13 is connected to the LEFT DRIVE PUMP FORWARD solenoid. A.

If all connectors are correctly installed, continue with step 3.

B.

If any connector is not correctly installed, Use frame 27 to ensure connectors X-18, X-16, X-17, and X-13 are installed correctly.

Check for proper connections to LH PUMP SWASH PLATE SENSOR and RH PUMP SWASH PLATE SENSOR. Ensure that connector X-94 is connected to the LH PUMP SWASH PLATE SENSOR. Ensure that connector X-93 is connected to the RH PUMP SWASH PLATE SENSOR. A.

If both connectors are correctly installed, continue with step 4.

B.

If either connector is not correctly installed, Use frame 27 to ensure connectors X-94 and X-93 are installed correctly.

Check Instrument Cluster for other Trouble Codes. A.

If the other Trouble Codes are active, follow the procedure for those first.

B.

If the no other Trouble Codes are active, the RH PUMP SWASH PLATE SENSOR has failed. Replace the RH PUMP SWASH PLATE SENSOR.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. 84522361 15/06/2011

A.50.A / 234

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 27 (A.30.A.88-C.20.E.27)

84522361 15/06/2011

A.50.A / 235

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4781- solenoid valve - Solenoid Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4781 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Two Speed operating mode is enabled with Diagnostic Trouble Code 4781. Cause: UCM has sent a signal to the 2 Speed Solenoid to energize, but the UCM does not sense proper voltage. (The fault is only activated when the Engine is on and solenoid output pin voltage falls out of the range of 1 - 8 V. Possible failure modes: 1.

2 Speed solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4781 - solenoid valve - Solenoid Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for open circuit. Disconnect connector X-2SPD from the 2 SPEED SOLENOID. Disconnect connector X-CN3A from the UCM. Using a multi-meter, check continuity between connector X-2SPD pin A and connector X-CN3A pin 25. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 564 (White) between connector X-2SPD pin A and connector X-CN3A pin 25. Repair or replace the wire.

Check for proper resistance in the 2 SPEED SOLENOID. Using a multi-meter to check for resistance between 2 SPEED SOLENOID pins A and B. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the 2 SPEED SOLENOID has developed an open. Replace the 2 SPEED SOLENOID.

C.

If resistance is 0 Ω, the 2 SPEED SOLENOID has shorted internally. Replace the 2 SPEED SOLENOID.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-2SPD pin B and ground. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 7, and 1 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3A-25 and CN1A-1. A.

If resistance is normal, continue with step 6. 84522361 15/06/2011

A.50.A / 236

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 07 (A.30.A.88-C.20.E.07) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 237

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4782- solenoid valve - Solenoid Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4782 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Two Speed is enabled with Diagnostic Trouble Code 4782. Cause: The UCM has sent a signal to the 2 Speed solenoid to energize, but there is no voltage detected. (The fault is only activated when Two Speed is on and solenoid output pin current is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

2 Speed Solenoid has failed.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 4782 - solenoid valve - Solenoid Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for a short to ground. Disconnect connector X-2SPD from the 2 SPEED SOLENOID. Disconnect connector X-CN3A from the UCM. Using a multi-meter, check for continuity between connector X-2SPD pin A, or connector X-CN3A pin 25 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 564 (White) between connector X-2SPD pin A and connector X-CN3A pin 25. Repair or replace the wire.

Check for proper resistance in the 2 SPEED SOLENOID. Using a multi-meter to check for resistance between 2 SPEED SOLENOID pins A and B. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the 2 SPEED SOLENOID has developed an open. Replace the 2 SPEED SOLENOID.

C.

If resistance is 0 Ω, the 2 SPEED SOLENOID has shorted internally. Replace the 2 SPEED SOLENOID.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3A-25 and CN1A-1. A.

If resistance is normal, continue with step 5.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. If multiple Diagnostic Trouble Codes are active, troubleshoot another Diagnostic Trouble Code. 84522361 15/06/2011

A.50.A / 238

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 07 (A.30.A.88-C.20.E.07) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 239

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

4783- solenoid valve - Solenoid Supply STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 4783 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 4783. Cause: UCM has sensed higher than normal voltage on the 2 Speed Solenoid. (The fault is only activated when Two Speed is off and 2 Speed Solenoid output voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of 2 Speed Solenoid.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 4783 - solenoid valve - Solenoid Supply STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for short to high. Disconnect connector X-CN3A from the UCM. Disconnect connector X-2SPD from the 2 SPEED SOLENOID. Using a multi-meter, check for voltage between connector X-2SPD pin A, or connector X-CN3A pin 25 and ground. A.

If there is no voltage, continue with step 3.

B.

If there is voltage, there is a short to high source on wire 564 (White) between connector X-2SPD pin A and connector X-CN3A pin 25. Repair or replace the wire.

Check for proper operation of the UCM. Reconnect connector X-CN3A to the UCM. Using a multi-meter, check for voltage between connector X-2SPD pin A and ground. A.

If voltage is greater than 8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 8 V, continue with step 4.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 07 (A.30.A.88-C.20.E.07)

84522361 15/06/2011

A.50.A / 240

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5051- Loader Pilot Interlock Valve (On/Off) - Solenoid Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5051 has an error priority of Red. Loader Hydraulics operating mode is disabled with Diagnostic Trouble Code 5051. Cause: UCM has sensed an open in the solenoid supply. (The fault is only activated when Engine is on and UCM pin voltage is between 1 - 8 V.) Possible failure modes: 1.

Loader Pilot Interlock Valve solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5051 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for open circuit. Disconnect connector X-PLTLK from the LOADER PILOT INTERLOCK VALVE SOLENOID. Disconnect connector X-CN2A from the UCM. Using a multi-meter, check continuity between connector X-PLTLK pin A and connector X-CN2A pin 4. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 536 (White) between connector X-PLTLK pin A and connector X-CN2A pin 4. Repair or replace the wire.

Check for proper resistance in the LOADER PILOT INTERLOCK VALVE SOLENOID. Using a multi-meter to check for resistance between LOADER PILOT INTERLOCK VALVE SOLENOID pins A and B. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the LOADER PILOT INTERLOCK VALVE SOLENOID has developed an open. Replace the LOADER PILOT INTERLOCK VALVE SOLENOID.

C.

If resistance is 0 Ω, the LOADER PILOT INTERLOCK VALVE SOLENOID has shorted internally. Replace the LOADER PILOT INTERLOCK VALVE SOLENOID.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-PLTLK pin B and ground. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 15, and 1 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2A-4 and CN1A-1. A.

If resistance is normal, continue with step 6. 84522361 15/06/2011

A.50.A / 241

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 15 (A.30.A.88-C.20.E.15) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)

84522361 15/06/2011

A.50.A / 242

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5052- Loader Pilot Interlock Valve (On/Off) - Solenoid Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5052 has an error priority of Red. Loader Hydraulics is disabled with Diagnostic Trouble Code 5052. Cause: The UCM has sent a signal to the Loader Pilot Interlock solenoid to energize, but there is no voltage detected. (The fault is only activated when Hydraulics are Enabled and Loader Pilot Interlock solenoid output pin current is high.) Possible failure modes: 1.

Loader Pilot Interlock Valve solenoid failed.

2.

Shorted wire in circuit.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5052 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for a short to ground. Disconnect connector X-CN2A from the UCM. Disconnect connector X-PLTLK from the LOADER PILOT INTERLOCK VALVE SOLENOID. Using a multi-meter, check for continuity between connector X-PLTLK pin A, or connector X-CN2A pin 4 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 536 (White) between connector X-PLTLK pin A and connector X-CN2A pin 4. Repair or replace the wire.

Check for proper resistance in the LOADER PILOT INTERLOCK VALVE SOLENOID. Using a multi-meter to check for resistance between LOADER PILOT INTERLOCK VALVE SOLENOID pins A and B. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the LOADER PILOT INTERLOCK VALVE SOLENOID has developed an open. Replace the LOADER PILOT INTERLOCK VALVE SOLENOID.

C.

If resistance is 0 Ω, the LOADER PILOT INTERLOCK VALVE SOLENOID has shorted internally. Replace the LOADER PILOT INTERLOCK VALVE SOLENOID.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2A-4 and CN1A-1. A.

If resistance is normal, continue with step 5.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring.

84522361 15/06/2011

A.50.A / 243

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 15 (A.30.A.88-C.20.E.15) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 244

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5053- Loader Pilot Interlock Valve (On/Off) - Solenoid Supply STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5053 has an error priority of Red. Disable Loader Hydraulics operating mode is enabled with Diagnostic Trouble Code 5053. Cause: The UCM has sent a signal to the Loader Pilot Interlock solenoid to de-energize, but voltage is still active. (The fault is only activated when Hydraulics are Disabled and Loader Pilot Interlock solenoid output pin voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 5053 - Loader Pilot Interlock Valve (On/Off) - Solenoid Supply STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for short to high. Disconnect connector X-PLTLK from the LOADER PILOT INTERLOCK VALVE SOLENOID. Disconnect connector X-CN2A from the UCM. Using a multi-meter, check for voltage between connector X-PLTLK pin A, or connector X-CN2A pin 4 and ground. A.

If there is no voltage, continue with step 3.

B.

If there is voltage, there is a short to high source on wire 536 (White) between connector X-PLTLK pin A and connector X-CN2A pin 4. Repair or replace the wire.

Check for proper operation of the UCM. Reconnect connector X-CN2A to the UCM. Using a multi-meter, check for voltage between connector X-PLTLK pin A and ground. A.

If voltage is greater than 8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 8 V, continue with step 4.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 15 (A.30.A.88-C.20.E.15) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 245

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5061- Port Lock Valve (On/Off) - Solenoid Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5061 has an error priority of Red. Disable Loader Hydraulics operating mode is enabled with Diagnostic Trouble Code 5061. Cause: UCM has sensed an open in the solenoid supply. (The fault is only activated when Engine is on and UCM pin voltage is between 1 - 8 V.) Possible failure modes: 1.

Loader Port Lock solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5061 - Port Lock Valve (On/Off) Solenoid Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Disconnect connector X-PORT_LK from the Loader Port Lock solenoid. Check for an open condition across the solenoid by using a multi-meter to check resistance between Loader Port Lock solenoid pins 1 and 2. A.

If the resistance is normal, continue with step 3.

B.

If the resistance is infinite, the solenoid is open. Replace the solenoid.

C.

If the resistance is 0 Ω, the solenoid is shorted. Replace the solenoid.

Disconnect connector X-CN2A from the UCM. Check for an open wire condition by using a multi-meter to check continuity between connector X-PORT_LK pin 1 and connector X-CN2A pin 5. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open on wire 537 (White) between connector X-PORT_LK pin 1 and connector X-CN2A pin 5. Replace the wire.

Check for continuity in the ground circuit. X-PORT_LK pin 2 and chassis ground.

Use a multi-meter to check for continuity between connector

A.

If there is no continuity, there is an open in the ground circuit. Use frames 26, 15, 4 and 1 to locate and isolate the faulty wire. Repair or replace the wire.

B.

If there is continuity, continue with step 5.

Check for proper operation of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2A-5 and CN1A-1. A.

If resistance is normal, continue with step 6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM. 84522361 15/06/2011

A.50.A / 246

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. If multiple Diagnostic Trouble Codes are active, troubleshoot another Diagnostic Trouble Code. This Diagnostic Trouble Code resolution does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before considering the UCM for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 15 (A.30.A.88-C.20.E.15) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)

84522361 15/06/2011

A.50.A / 247

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5062- Port Lock Valve (On/Off) - Solenoid Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5062 has an error priority of Red. Disable Loader Hydraulics operating mode is enabled with Diagnostic Trouble Code 5062. Cause: The UCM has sent a signal to the Loader Port Lock Solenoid to energize, but there is no voltage detected. (The fault is only activated when Hydraulics are on and Loader Lock is off and Aux Override is off and solenoid output pin current is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Loader Port Lock Solenoid has failed.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 5062 - Port Lock Valve (On/Off) Solenoid Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for a short to ground. Disconnect connector X-PORT_LK from the LOADER PORT LOCK SOLENOID. Disconnect connector X-CN2A from the UCM. Disconnect connector X-TELE from the TELEMATICS CONNECTOR. Using a multi-meter, check for continuity between connector X-PORT_LK pin 1 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 537 (White) between SPLICE 187 and connector X-CN2A pin 5, or on wire 304 (White) between SPLICE 187 and connector X-PORT_LK pin 1, or on wire 308 (Yellow) between connector X-TELE pin E and SPLICE 187. Use Frames 15 and 32 to troubleshoot and isolate the fault. Repair or replace faulty wire.

Check for proper resistance in the LOADER PORT LOCK SOLENOID. Using a multi-meter to check for resistance between LOADER PORT LOCK SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 4.

B.

If resistance is infinite, the LOADER PORT LOCK SOLENOID has developed an open. Replace the LOADER PORT LOCK SOLENOID.

C.

If resistance is 0 Ω, the LOADER PORT LOCK SOLENOID has shorted internally. Replace the LOADER PORT LOCK SOLENOID.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2A-5 and CN1A-1. A.

If resistance is normal, continue with step 5.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

84522361 15/06/2011

A.50.A / 248

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. If multiple Diagnostic Trouble Codes are active, troubleshoot another Diagnostic Trouble Code. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 15 (A.30.A.88-C.20.E.15) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 30 (A.30.A.88-C.20.E.30)

84522361 15/06/2011

A.50.A / 249

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5063- Port Lock Valve (On/Off) - Solenoid Supply STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5063 has an error priority of Red. Disable Loader Hydraulics operating mode is enabled with Diagnostic Trouble Code 5063. Cause: UCM has sensed higher than normal voltage on the Port Lock Valve Solenoid. (The fault is only activated when Hydraulics are off or Loader Lock is on or Aux Override is on and Port Lock Valve voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Port Lock Valve Solenoid.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 5063 - Port Lock Valve (On/Off) Solenoid Supply STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for a short to high. Disconnect connector X-PORT_LK from PORT LOCK VALVE SOLENOID. Disconnect connector X-CN2A from the UCM. Disconnect connector X-TELE from the TELEMATICS CONNECTOR. Using a multi-meter, check voltage between connector X-PORT_LK pin 1 and ground. A.

If there is no voltage, continue with step 3.

B.

If there is voltage, there is a short to high condition on wire 537 (White) between SPLICE 187 and connector X-CN2A pin 5, or on wire 304 (White) between SPLICE 187 and connector X-PORT_LK pin 1, or on wire 308 (Yellow) between connector X-TELE pin E and SPLICE 187. Use Frames 15 and 32 to troubleshoot and isolate the fault. Visually inspect the affected wires for damage. Repair or replace faulty wire.

Check for proper operation of the UCM. Reconnect connector X-CN2A to the UCM. Using a multi-meter, check for voltage between connector X-PORT_LK pin 1 and ground. A.

If voltage is greater than 8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 8 V, continue with step 4.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 15 (A.30.A.88-C.20.E.15) Wiring harness - Electrical schematic frame 30 (A.30.A.88-C.20.E.30) 84522361 15/06/2011

A.50.A / 250

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5121-R joy F-B axis - Pin A STP / STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5121 has an error priority of Amber. In ISO Pattern, Limp Home Implement operating mode is enabled with Diagnostic Trouble Code 5121. In H-Pattern, Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 5121. Cause: UCM has sensed that the 5 V signal has failed. (The fault is only activated when Ignition is On and Joystick voltage falls out of the range of 0.2 V to 4.8 V. Possible failure modes: 1.

Shorted wire in circuit.

2.

Open wire in circuit.

3.

Failure of RIGHT HAND CONTROL HANDLE.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5121 - R joy F-B axis - Pin A STP / STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 13.

Check for open circuit. Disconnect connector X-UJMR from the RIGHT HAND CONTROL HANDLE. Disconnect connector X-CN4A from the UCM. Using a multi-meter, check continuity between connector X-UJMR pin 3 and connector X-CN4A pin 17. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 561 (White) between connector X-UJMR pin 3 and connector X-CN4A pin 17. continue with step 3.

Check for open circuit. Disconnect connector X-ECC5A from X-ECC5B. Using a multi-meter, check continuity between connector X-ECC5B pin 9 and connector X-CN4A pin 17. A.

If there is no continuity, there is an open wire condition on wire 561 (White) between connector X-ECC5B pin 9 and connector X-CN4A pin 17. Repair or replace the wire.

B.

If there is continuity, there is an open wire condition on wire 561 (White) between connector X-ECC5A pin 9 and connector X-UJMR pin 3, or connectors X-ECC5A and X-ECC5B are not making a good connection at pin 9. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-UJMR pin 3, or connector X-CN4A pin 17 and ground. A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 561 (White) between connector X-UJMR pin 3 and connector X-CN4A pin 17. Continue with step 5.

Locate the short to ground. Disconnect connector X-ECC5A from connector X-ECC5B. Using a multi-meter, check for continuity between connector X-ECC5B pin 9, or connector X-CN4A pin 17 and ground.

84522361 15/06/2011

A.50.A / 251

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

9.

10.

11.

12.

13.

A.

If there is no continuity, there is a short to ground on wire 561 (White) between connector X-UJMR pin 3 and X-ECC5A pin 9. Repair or replace the shorted conductor.

B.

If there is continuity, there is a short to ground condition on wire 561 (White) between connector X-ECC5B pin 9 and connector X-CN4A pin 17. Repair or replace the shorted wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-UJMR pin 3, or connector X-CN4A pin 17 and ground. A.

If there is no voltage, continue with step 8.

B.

If voltage greater than 4.8 V, there is a short to high source on wire 561 (White) between connector X-UJMR pin 3 and connector X-CN4A pin 17. Continue with step 7.

Locate short to high. Disconnect connector X-ECC5A from X-ECC5B. Using a multi-meter, check for voltage between connector X-UJMR pin 3 and ground. A.

If there is no voltage, there is a short to high source on wire 561 (White) between connector X-ECC5B pin 9 and connector X-CN4A pin 17. Repair or replace the wire.

B.

If voltage greater than 4.8 V, there is a short to high source on wire 561 (White) between connector X-UJMR pin 3 and connector X-ECC5A pin 9. Repair or replace the wire.

Check for proper resistance in the RIGHT HAND CONTROL HANDLE. Using a multi-meter to check for resistance between RIGHT HAND CONTROL HANDLE pins 3 and 4. A.

If resistance is normal, continue with step 9.

B.

If resistance is infinite, the RIGHT HAND CONTROL HANDLE has developed an open. Replace the RIGHT HAND CONTROL HANDLE.

C.

If resistance is 0 Ω, the RIGHT HAND CONTROL HANDLE has shorted internally. Replace the RIGHT HAND CONTROL HANDLE.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-UJMR pin 4 and ground. A.

If there is continuity, continue with step 10.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 23, 19, 25 and 1 to troubleshoot and isolate the faulty wire.

Check for proper operation of the RIGHT HAND CONTROL HANDLE. Reconnect connector X-UJMR to the RIGHT HAND CONTROL HANDLE. Disconnect connector X-ECC5B from connector X-ECC5A. Using a multi-meter, check for voltage between connector X-ECC5A pin 9 and ground. A.

If voltage is greater than 4.8 V, the RIGHT HAND CONTROL HANDLE has failed. Replace the RIGHT HAND CONTROL HANDLE.

B.

If voltage is less than 4.8 V, continue with step 11.

Check for proper operation of the UCM. Reconnect connector X-CN4A to the UCM. Using a multi-meter, check for voltage between connector X-ECC5B pin 9 and ground. A.

If voltage is greater than 4.8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 4.8 V, continue with step 12.

Check for a short in the UCM. Completely power down the UCM by removing all six connectors. Using a multimeter, check for resistance between UCM pins CN4A-17 and CN1A-1. A.

If resistance is about 99.5 K Ω, continue with step 13.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 150 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent 84522361 15/06/2011

A.50.A / 252

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19)

84522361 15/06/2011

A.50.A / 253

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5122- R joy F-B axis - Pin B STP / STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5122 has an error priority of Amber. When in H-Pattern, Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 5122. When in ISO Pattern, Limp Home Implement operating mode is enabled with Diagnostic Trouble Code 5122. Cause: UCM has sensed that the 5 V signal has failed. (The fault is only activated when Ignition is On and Joystick voltage falls out of the range of 0.2 V to 4.8 V. Possible failure modes: 1.

Shorted wire in circuit.

2.

Open wire in circuit.

3.

Failure of RIGHT HAND CONTROL HANDLE.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5122 - R joy F-B axis - Pin B STP / STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 14.

Check for open circuit. Disconnect connector X-UJMR from the RIGHT HAND CONTROL HANDLE. Disconnect connector X-CN1B from the UCM. Using a multi-meter, check continuity between connector X-UJMR pin 9 and connector X-CN1B pin 13. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 560 (Green) between connector X-UJMR pin 9 and connector X-CN1B pin 13. Continue with step 3.

Locate the open circuit. Disconnect connector X-ECC4A from X-ECC4B. Using a multi-meter, check continuity between connector X-ECC4B pin 14 and connector X-CN1B pin 13. A.

If there is no continuity, there is an open wire condition on wire 560 (Green) between connector X-ECC4B pin 14 and connector X-CN1B pin 13. Repair or replace the wire.

B.

If there is continuity, continue with step 4

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC4A pin 14 and connector X-UJMR pin 9. A.

If there is no continuity, there is an open wire condition on wire 560 (Green) between connector X-ECC4A pin 14 and connector X-UJMR pin 9. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC4A and X-ECC4B are not making a good connection at pin 14. Repair the connector.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-UJMR pin 9, or connector X-CN1B pin 13 and ground. A.

If there is no continuity, continue with step 7. 84522361 15/06/2011

A.50.A / 254

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

10.

11.

12.

13.

If there is continuity, there is a short to ground condition on wire 560 (Green) between connector X-UJMR pin 9 and connector X-CN1B pin 13. Continue with step 6.

Locate the short to ground. Disconnect connector X-ECC4A from connector X-ECC4B. Using a multi-meter, check for continuity between connector X-ECC4B pin 14, or connector X-CN1B pin 13 and ground. A.

If there is no continuity, there is a short to ground on wire 560 (Green) between connector X-UJMR pin 9 and X-ECC4A pin 14. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 560 (Green) between connector X-ECC4B pin 14 and connector X-CN1B pin 13. Repair or replace the shorted wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-UJMR pin 9, or connector X-CN1B pin 13 and ground. A.

If there is no voltage, continue with step 9.

B.

If voltage greater than 4.8 V, there is a short to high source on wire 560 (Green) between connector X-UJMR pin 9 and connector X-CN1B pin 13. Continue with step 8.

Locate the short to high. Disconnect connector X-ECC4A from X-ECC4B. Using a multi-meter, check for voltage between connector X-UJMR pin 9 and ground. A.

If there is no voltage, there is a short to high source on wire 560 (Green) between connector X-ECC4B pin 14 and connector X-CN1B pin 13. Repair or replace the wire.

B.

If voltage greater than 4.8 V, there is a short to high source on wire 560 (Green) between connector X-UJMR pin 9 and connector X-ECC4A pin 14. Repair or replace the wire.

Check for proper resistance in the RIGHT HAND CONTROL HANDLE. Using a multi-meter to check for resistance between RIGHT HAND CONTROL HANDLE pins 9 and 10. A.

If resistance is around 3.1 K Ω, continue with step 10.

B.

If resistance is infinite, the RIGHT HAND CONTROL HANDLE has developed an open. Replace the RIGHT HAND CONTROL HANDLE.

C.

If resistance is 0 Ω, the RIGHT HAND CONTROL HANDLE has shorted internally. Replace the RIGHT HAND CONTROL HANDLE.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-UJMR pin 10 and ground. A.

If there is continuity, continue with step 11.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 23, 19, 25 and 1 to troubleshoot and isolate the faulty wire.

Check for proper operation of the RIGHT HAND CONTROL HANDLE. Reconnect connector X-UJMR to the RIGHT HAND CONTROL HANDLE. Disconnect connector X-ECC4B from connector X-ECC4A. Using a multi-meter, check for voltage between connector X-ECC4A pin 14 and ground. A.

If voltage is greater than 4.8 V, the RIGHT HAND CONTROL HANDLE has failed. Replace the RIGHT HAND CONTROL HANDLE.

B.

If voltage is less than 4.8 V, continue with step 12.

Check for proper operation of the UCM. Reconnect connector X-CN1B to the UCM. Using a multi-meter, check for voltage between connector X-ECC4B pin 14 and ground. A.

If voltage is greater than 4.8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 4.8 V, continue with step 13.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-13 and CN1A-1. A.

If resistance is around 56 K Ω, continue with step 14. 84522361 15/06/2011

A.50.A / 255

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

14.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19)

84522361 15/06/2011

A.50.A / 256

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5124- R joy F-B axis - in-range fault L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5124 has an error priority of Red. When in H-Pattern, Ground Drive operating mode is disabled with Diagnostic Trouble Code 5124. When in ISO-Pattern, Disable Boom operating mode is enabled with Diagnostic Trouble Code 5124. Cause: UCM has sensed that the RIGHT HAND CONTROL HANDLE has failed. (The fault is only activated when Ignition is On and the sum of the Right Hand Joystick output voltages falls out of the range of 4.8 V to 5.2 V.) Possible failure modes: 1.

Failure of the RIGHT HAND CONTROL HANDLE.

2.

Open or shorted wire in circuit.

3.

Failure of the UCM.

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 5124 - R joy F-B axis - in-range fault is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check Instrument Cluster for other Trouble Codes. A.

If the other Trouble Codes are active, follow the procedure for those first.

B.

If the no other Trouble Codes are active, the RIGHT HAND CONTROL HANDLE has failed. Replace the RIGHT HAND CONTROL HANDLE.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23)

84522361 15/06/2011

A.50.A / 257

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5131- R joy R-L axis (ISO/H Pattern) - Pin A STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5131 has an error priority of Amber. Limp Home Implement operating mode is enabled with Diagnostic Trouble Code 5131. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Engine is On and pin voltage is less than 0.2 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of RIGHT HAND CONTROL HANDLE.

3.

Open wire in circuit.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5131 - R joy R-L axis (ISO/H Pattern) - Pin A STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 9.

Check for open circuit. Disconnect connector X-UJMR from RIGHT HAND CONTROL HANDLE. Disconnect connector X-CN4A from UCM. Using a multi-meter, check continuity between connector X-UJMR, pin 2 and connector X-CN4A, pin 24. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 549 (White) between connector X-UJMR, pin 2 and connector X-CN4A, pin 24. Continue with step 3 to isolate the fault.

Check for open circuit. Disconnect connector X-ECC5B from X-ECC5A. Using a multi-meter, check continuity between connector X-ECC5B, pin 3 and connector X-CN4A, pin 24. A.

If there is continuity, there is an open wire condition on wire 549 (White) between connector X-UJMR, pin 2 and connector X-ECC5A, pin 3, or connectors X-ECC5A and X-ECC5B are not making a good connection at pin 3. Repair or replace the wire.

B.

If there is no continuity, there is an open wire condition on wire 549 (White) between connector X-ECC5B, pin 3 and connector X-CN4A, pin 24. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-CN4A pin 24, or connector X-UJMR pin 2 and ground. A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 549 (White) between connector X-CN4A pin 24 and connector X-UJMR pin 2. Continue with 5 to isolate the fault.

Check for a short to ground. Disconnect connector X-ECC5A from X-ECC5B. Using a multi-meter, check for continuity between connector X-ECC5A, pin 3 and ground. A.

If there is continuity, there is a short to ground condition on wire 549 (White) between connector X-UJMR, pin 2 and connector X-ECC5A, pin 3. Repair or replace the wire. 84522361 15/06/2011

A.50.A / 258

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

If there is no continuity, there is a short to ground condition on wire 549 (White) between connector X-CN4A, pin 24 and connector X-UJMR, pin 2. Repair or replace the wire.

Check for proper resistance in the RIGHT HAND CONTROL HANDLE by using a multi-meter to check for resistance between RIGHT HAND CONTROL HANDLE pins 2 and 4. A.

If resistance is normal, continue with step 7.

B.

If resistance is infinite, the RIGHT HAND CONTROL HANDLE has developed an open, replace the RIGHT HAND CONTROL HANDLE.

C.

If resistance is 0 Ω, the RIGHT HAND CONTROL HANDLE has shorted internally. Replace the RIGHT HAND CONTROL HANDLE.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-UJMR pin 4 and ground. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 23, 19, 25 and 1 to troubleshoot and isolate the faulty wire.

Check for a short in the UCM. Completely power down the UCM by removing all six connectors. Using a multimeter, check for resistance between UCM pins CN4A-24 and CN1A-1. A.

If resistance is normal, continue with step 9.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19)

84522361 15/06/2011

A.50.A / 259

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5132- R joy R-L axis (ISO/H Pattern) - Pin A STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5132 has an error priority of Amber. Limp Home Implement operating mode is enabled with Diagnostic Trouble Code 5132. Cause: UCM has sensed that the 5 V signal has failed high. (The fault is only activated when Ignition is On and Right Joystick Voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Right Joystick.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5132 - R joy R-L axis (ISO/H Pattern) - Pin A STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for short to positive condition. Disconnect connector X-UJMR from the RIGHT HAND CONTROL MODULE Disconnect connector X-CN4A from the UCM. Using a multi-meter, check for voltage between connector X-UJMR pin 2, or connector X-CN4A pin 24 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 549 (White) between connector X-UJMR pin 2 and connector X-CN4A pin 24. Continue with step 3.

Locate short to positive condition. Disconnect connector X-ECC5B from X-ECC5A. Using a multi-meter, check for voltage between connector X-ECC5B pin 3 and ground. A.

If there is no voltage, there is a short to positive condition on wire 549 (White) between connector X-UJMR pin 2 and connector X-ECC5A pin 3. Repair or replace the wire.

B.

If there is voltage, there is a short to positive condition on wire 549 (White) between connector X-ECC5B pin 3 and connector X-CN4A pin 24. Repair or replace the wire.

Check for proper operation of the RIGHT HAND CONTROL MODULE. Reconnect connector X-UJMR to the RIGHT HAND CONTROL MODULE. Using a multi-meter, check for voltage between connector X-ECC5A pin 3 and ground. A.

If there is greater than 4.8 V, the RIGHT HAND CONTROL MODULE has failed. Replace the RIGHT HAND CONTROL MODULE.

B.

If there is less than 4.8 V,continue with step 6.

Check for proper operation of the UCM. Reconnect connector X-CN4A to the UCM. Using a multi-meter, check for voltage between connector X-ECC5B pin 3 and ground. A.

If voltage is greater than 4.8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 4.8 V, continue with step 6. 84522361 15/06/2011

A.50.A / 260

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 261

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5134- R joy R-L axis (ISO/H Pattern) - Pin B STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5134 has an error priority of Amber. Limp Home Implement operating mode is enabled with Diagnostic Trouble Code 5134. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Engine is On and pin B voltage is less than 0.2 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of RIGHT HAND CONTROL HANDLE.

3.

Open wire in circuit.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5134 - R joy R-L axis (ISO/H Pattern) - Pin B STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 9.

Check for open circuit. Disconnect connector X-UJMR from RIGHT HAND CONTROL HANDLE. Disconnect connector X-CN3A from UCM. Using a multi-meter, check continuity between connector X-UJMR pin 8 and connector X-CN3A pin 11. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 548 (Green) between connector X-UJMR pin 8 and connector X-CN3A pin 11. Continue with step 3 to isolate the fault.

Check for open circuit. Disconnect connector X-ECC4B from X-ECC4A. Using a multi-meter, check continuity between connector X-ECC4B pin 13 and connector X-CN3A pin 11. A.

If there is continuity, there is an open wire condition on wire 548 (Green) between connector X-UJMR pin 8 and connector X-ECC4A pin 13, or connectors X-ECC4A and X-ECC4B are not making a good connection at pin 13. Repair or replace the wire.

B.

If there is no continuity, there is an open wire condition on wire 548 (Green) between connector X-ECC4B pin 13 and connector X-CN3A pin 11. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-UJMR pin 8, or connector X-CN3A pin 11 and ground. A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 548 (Green) between connector X-UJMR pin 8 and connector X-CN3A pin 11. Continue with step 5.

Locate the short to ground. Disconnect connector X-ECC4A from connector X-ECC4B. Using a multi-meter, check for continuity between connector X-ECC4B pin 13, or connector X-CN3A pin 13 and ground. A.

If there is no continuity, there is a short to ground on wire 548 (Green) between connector X-UJMR pin 8 and X-ECC4A pin 13. Repair or replace the shorted conductor. 84522361 15/06/2011

A.50.A / 262

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

If there is continuity, there is a short to ground condition on wire 548 (Green) between connector X-ECC4B pin 13 and connector X-CN3A pin 11. Repair or replace the shorted wire.

Check for proper resistance in the RIGHT HAND CONTROL HANDLE by using a multi-meter to check for resistance between RIGHT HAND CONTROL HANDLE pins 8 and 10. A.

If resistance is normal, continue with step 7.

B.

If resistance is infinite, the RIGHT HAND CONTROL HANDLE has developed an open, replace the RIGHT HAND CONTROL HANDLE.

C.

If resistance is 0 Ω, the RIGHT HAND CONTROL HANDLE has shorted internally. Replace the RIGHT HAND CONTROL HANDLE.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-UJMR pin 10 and ground. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 23, 19, 25 and 1 to troubleshoot and isolate the faulty wire.

Check for a short in the UCM. Completely power down the UCM by removing all six connectors. Using a multimeter, check for resistance between UCM pins CN3A-11 and CN1A-1. A.

If resistance is normal, continue with step 9.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 263

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5135- R joy R-L axis (ISO/H Pattern) - Pin B STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5135 has an error priority of Amber. Limp Home Implement operating mode is enabled with Diagnostic Trouble Code 5135. Cause: UCM has sensed that the 5 V signal has failed high. (The fault is only activated when Ignition is On and Right Joystick Voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Right Joystick.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5135 - R joy R-L axis (ISO/H Pattern) - Pin B STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for short to positive condition. Disconnect connector X-UJMR from the RIGHT HAND CONTROL MODULE Disconnect connector X-CN3A from the UCM. Using a multi-meter, check for voltage between connector X-UJMR pin 8, or connector X-CN3A pin 11 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 548 (Green) between connector X-UJMR pin 8 and connector X-CN3A pin 11. Continue with step 3.

Locate short to positive condition. Disconnect connector X-ECC4B from X-ECC4A. Using a multi-meter, check for voltage between connector X-ECC4B pin 13 and ground. A.

If there is no voltage, there is a short to positive condition on wire 548 (Green) between connector X-UJMR pin 8 and connector X-ECC4A pin 13. Repair or replace the wire.

B.

If there is voltage, there is a short to positive condition on wire 548 (Green) between connector X-ECC4B pin 13 and connector X-CN3A pin 11. Repair or replace the wire.

Check for proper operation of the RIGHT HAND CONTROL MODULE. Reconnect connector X-UJMR to the RIGHT HAND CONTROL MODULE. Using a multi-meter, check for voltage between connector X-ECC4A pin 13 and ground. A.

If there is greater than 4.8 V, the RIGHT HAND CONTROL MODULE has failed. Replace the RIGHT HAND CONTROL MODULE.

B.

If there is less than 4.8 V,continue with step 5.

Check for proper operation of the UCM. Reconnect connector X-CN3A to the UCM. Using a multi-meter, check for voltage between connector X-ECC4B pin 13 and ground. A.

If voltage is greater than 4.8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 4.8 V, continue with step 6. 84522361 15/06/2011

A.50.A / 264

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 265

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5137- R joy R-L axis (ISO/H Pattern) - in-range fault L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5137 has an error priority of Red. Disable Bucket operating mode is enabled with Diagnostic Trouble Code 5137. Cause: UCM has sensed that the RIGHT HAND CONTROL HANDLE has failed. (The fault is only activated when Ignition is On and the sum of the Right Hand Joystick output voltages falls out of the range of 4.8 V to 5.2 V.) Possible failure modes: 1.

Failure of the RIGHT HAND CONTROL HANDLE

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 5137 - R joy R-L axis (ISO/H Pattern) - in-range fault is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check Instrument Cluster for other Trouble Codes. A.

If the other Trouble Codes are active, follow the procedure for those first.

B.

If the no other Trouble Codes are active, the RIGHT HAND CONTROL HANDLE has failed. Replace the RIGHT HAND CONTROL HANDLE.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23)

84522361 15/06/2011

A.50.A / 266

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5141- Aux thumbwheel axis - Pin A STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5141 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Aux operating mode is enabled with Diagnostic Trouble Code 5141. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Ignition is On and Aux Thumbwheel Axis voltage is less than 0.2 V. Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Right Hand Control Handle.

3.

Open wire in circuit.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5141 - Aux thumbwheel axis - Pin A STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 10.

Check for open circuit. Disconnect connector X-403 from the RIGHT HAND CONTROL HANDLE. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check continuity between connector X-403 pin 2 and connector X-CN2B pin 28. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 547 (Yellow) between connector X-403 pin 2 and connector X-CN2B pin 28. continue with step 3.

Locate the open circuit. Disconnect connector X-ECC6A from X-ECC6B. Using a multi-meter, check continuity between connector X-ECC6B pin 14 and connector X-CN2B pin 28. A.

If there is no continuity, there is an open wire condition on wire 547 (Yellow) between connector X-ECC6B pin 14 and connector X-CN2B pin 28. Repair or replace the wire.

B.

If there is continuity, continue with step 4.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC6A pin 14 and connector X-403 pin 2. A.

If there is no continuity, there is an open wire condition on wire 547 (Yellow) between connector X-ECC6A pin 14 and connector X-403 pin 2. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC6A and X-ECC6B are not making a good connection at pin 14. Repair the connector.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-403 pin 2, or connector X-CN2B pin 28 and ground. A.

If there is no continuity, continue with step 7. 84522361 15/06/2011

A.50.A / 267

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

10.

If there is continuity, there is a short to ground condition on wire 547 (Yellow) between connector X-403 pin 2 and connector X-CN2B pin 28. Continue with step 6.

Locate the short to ground. Disconnect connector X-ECC4A from connector X-ECC4B. Using a multi-meter, check for continuity between connector X-ECC4B pin 14, or connector X-CN2B pin 28 and ground. A.

If there is no continuity, there is a short to ground on wire 547 (Yellow) between connector X-UJMR pin 2 and X-ECC4A pin 14. Repair or replace the shorted conductor.

B.

If there is continuity, there is a short to ground condition on wire 547 (Yellow) between connector X-ECC4B pin 14 and connector X-CN2B pin 28. Repair or replace the shorted wire.

Check for proper resistance in the RIGHT HAND CONTROL HANDLE. Using a multi-meter to check for resistance between RIGHT HAND CONTROL HANDLE pins 2 and 3. A.

If resistance is normal, continue with step 8.

B.

If resistance is infinite, the RIGHT HAND CONTROL HANDLE has developed an open. Replace the RIGHT HAND CONTROL HANDLE.

C.

If resistance is 0 Ω, the RIGHT HAND CONTROL HANDLE has shorted internally. Replace the RIGHT HAND CONTROL HANDLE.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-403 pin 3 and ground. A.

If there is continuity, continue with step 9.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 25, 19, 2 and 1 to troubleshoot and isolate the faulty wire.

Check for a short in the UCM. Completely power down the UCM by removing all six connectors. Using a multimeter, check for resistance between UCM pins CN2B-28 and CN1A-1. A.

If resistance is normal, continue with step 10.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19) harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 268

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5142- Aux thumbwheel axis - Pin A STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5142 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Aux operating mode is enabled with Diagnostic Trouble Code 5142. Cause: UCM has sensed higher than normal voltage on the Aux Thumbwheel Pin A. (The fault is only activated when Ignition is on and Aux Thumbwheel Pin A voltage is greater than 4.8 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Right Hand Control Handle has internal failure.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5142 - Aux thumbwheel axis - Pin A STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for short to high. Disconnect connector X-403 from the RIGHT HAND CONTROL HANDLE. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check for voltage between connector X-403 pin 2, or connector X-CN2B pin 28 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 547 (Yellow) between connector X-403 pin 2 and connector X-CN2B pin 28. Continue with step 3.

Locate the short to high. Disconnect connector X-ECC6A from X-ECC6B. Using a multi-meter, check for voltage between connector X-403 pin 2 and ground. A.

If there is no voltage, there is a short to high source on wire 547 (Yellow) between connector X-ECC6B pin 14 and connector X-CN2B pin 28. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 547 (Yellow) between connector X-403 pin 2 and connector X-ECC6A pin 14. Repair or replace the wire.

Check for proper operation of the RIGHT HAND CONTROL HANDLE. Reconnect connector X-403 to the RIGHT HAND CONTROL HANDLE. Disconnect connector X-ECC6B from connector X-ECC6A. Using a multi-meter, check for voltage between connector X-ECC6A pin 14 and ground. A.

If voltage is greater than 5.3 V, the RIGHT HAND CONTROL HANDLE has failed. Replace the RIGHT HAND CONTROL HANDLE.

B.

If voltage is less than 5.3 V, continue with step 5.

Check for proper operation of the UCM. Reconnect connector X-CN2B to the UCM. Using a multi-meter, check for voltage between connector X-ECC6B pin 14 and ground. A.

If voltage is greater than 5.3 V, the UCM has failed. Replace the UCM. 84522361 15/06/2011

A.50.A / 269

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

If voltage is less than 5.3 V, continue with step 6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 270

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5144- Aux thumbwheel axis - Pin B STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Fault code 5144 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Aux operating mode is enabled with Fault code 5144. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Engine is On and Aux Thumbwheel voltage is less than 0.2 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Right Hand Control Handle.

3.

Open wire in circuit.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5144 - Aux thumbwheel axis - Pin B STG / OC is present. A.

If the fault is present, continue with step 2.

B.

If the fault is not present, the fault may be intermittent and not currently active, continue with step 9.

Check for open circuit. Disconnect connector X-403 from the RIGHT HAND CONTROL HANDLE. Disconnect connector X-CN4B from the UCM. Using a multi-meter, check continuity between connector X-403 pin 11 and connector X-CN4B pin 21. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 546 (Yellow) between connector X-403 pin 11 and connector X-CN4B pin 21. Continue with step 3.

Locate the open circuit. Disconnect connector X-ECC6A from X-ECC6B. Using a multi-meter, check continuity between connector X-ECC6B pin 11 and connector X-CN4B pin 21. A.

If there is no continuity, there is an open wire condition on wire 546 (Yellow) between connector X-ECC6B pin 11 and connector X-CN4B pin 21. Repair or replace the wire.

B.

If there is continuity, there is an open wire condition on wire 546 (Yellow) between connector X-ECC6A pin 11 and connector X-403 pin 11, or connectors X-ECC6A and X-ECC6B are not making a good connection at pin 11. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-403 pin 11, or connector X-CN4B pin 21 and ground. A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 546 (Yellow) between connector X-403 pin 9 and connector X-CN4B pin 21. Continue with step 5.

Locate the short to ground. Disconnect connector X-ECC6A from connector X-ECC6B. Using a multi-meter, check for continuity between connector X-ECC6B pin 11, or connector X-CN4B pin 21 and ground. 84522361 15/06/2011

A.50.A / 271

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

9.

A.

If there is no continuity, there is a short to ground on wire 546 (Yellow) between connector X-403 pin 11 and X-ECC6A pin 11. Repair or replace the shorted conductor.

B.

If there is continuity, there is a short to ground condition on wire 546 (Yellow) between connector X-ECC6B pin 11 and connector X-CN4B pin 21. Repair or replace the shorted wire.

Check for proper resistance in the RIGHT HAND CONTROL HANDLE. Using a multi-meter to check for resistance between RIGHT HAND CONTROL HANDLE pins 11 and 12. A.

If resistance is normal, continue with step 7.

B.

If resistance is infinite, the RIGHT HAND CONTROL HANDLE has developed an open. Replace the RIGHT HAND CONTROL HANDLE.

C.

If resistance is 0 Ω, the RIGHT HAND CONTROL HANDLE has shorted internally. Replace the RIGHT HAND CONTROL HANDLE.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-403 pin 12 and ground. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 25, 19, 2 and 1 to troubleshoot and isolate the faulty wire.

Check for a short in the UCM. Completely power down the UCM by removing all six connectors. Using a multimeter, check for resistance between UCM pins CN4B-21 and CN1A-1. A.

If resistance is normal, continue with step 9.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This fault code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the fault code and continue operation. harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 272

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5145-Aux thumbwheel axis - Pin B STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5145 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Aux operating mode is enabled with Diagnostic Trouble Code 5145. Cause: UCM has sensed higher than normal voltage on the Aux Thumbwheel Pin B. (The fault is only activated when Ignition is on and Aux Thumbwheel Pin B voltage is greater than 4.8 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Right Hand Control Handle has internal failure.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5145 - Aux thumbwheel axis - Pin B STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for short to high. Disconnect connector X-403 from the RIGHT HAND CONTROL HANDLE. Disconnect connector X-CN4B from the UCM. Using a multi-meter, check for voltage between connector X-403 pin 11, or connector X-CN4B pin 21 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 546 (Yellow) between connector X-403 pin 11 and connector X-CN4B pin 21. Continue with step 3.

Locate the short to high. Disconnect connector X-ECC6A from X-ECC6B. Using a multi-meter, check for voltage between connector X-403 pin 11 and ground. A.

If there is no voltage, there is a short to high source on wire 546 (Yellow) between connector X-ECC6B pin 11 and connector X-CN4B pin 21. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 546 (Yellow) between connector X-403 pin 11 and connector X-ECC6A pin 11. Repair or replace the wire.

Check for proper operation of the RIGHT HAND CONTROL HANDLE. Reconnect connector X-403 to the RIGHT HAND CONTROL HANDLE. Disconnect connector X-ECC6B from connector X-ECC6A. Using a multi-meter, check for voltage between connector X-ECC6A pin 11 and ground. A.

If voltage is greater than 4.8 V, the RIGHT HAND CONTROL HANDLE has failed. Replace the RIGHT HAND CONTROL HANDLE.

B.

If voltage is less than 4.8 V, continue with step 5.

Check for proper operation of the UCM. Reconnect connector X-CN4B to the UCM. Using a multi-meter, check for voltage between connector X-ECC6B pin 11 and ground. A.

If voltage is greater than 4.8 V, the UCM has failed. Replace the UCM. 84522361 15/06/2011

A.50.A / 273

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

If voltage is less than 4.8 V, continue with step 6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 274

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5147- Aux thumbwheel axis - in-range fault L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5147 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Aux operating mode is enabled with Diagnostic Trouble Code 5147. Cause: UCM has sensed that the AUX THUMBWHEEL has failed. (The fault is only activated when Engine is On and the sum of the Aux Thumbwheel output voltages falls out of the range of 4.8 V to 5.2 V.) Possible failure modes: 1.

Failure of the AUX THUMBWHEEL

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 5147 - Aux thumbwheel axis - in-range fault is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check Instrument Cluster for other Trouble Codes. A.

If the other Trouble Codes are active, follow the procedure for those first.

B.

If the no other Trouble Codes are active, the AUX THUMBWHEEL has failed. Replace the AUX THUMBWHEEL.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19)

84522361 15/06/2011

A.50.A / 275

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5201- L joystick L-R axis - Pin A STP / STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5201 has an error priority of Amber. In ISO Pattern, Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 5201. In H-Pattern, Limp Home Implement operating mode is enabled with Diagnostic Trouble Code 5201. Cause: UCM has sensed that the 5 V signal has failed. (The fault is only activated when Ignition is On and the sum of the Left Hand Joystick output voltages falls out of the range of 0.2 V to 4.8 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Open wire in circuit.

3.

Failure of LEFT HAND CONTROL HANDLE.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5201 - L joystick L-R axis - Pin A STP / STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 14.

Check for open circuit. Disconnect connector X-UJML from the LEFT HAND CONTROL HANDLE. Disconnect connector X-CN4A from the UCM. Using a multi-meter, check continuity between connector X-UJML pin 2 and connector X-CN4A pin 25. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 567 (White) between connector X-UJML pin 2 and connector X-CN4A pin 25. Continue with step 3.

Locate the open circuit. Disconnect connector X-ECC6B from X-ECC6A. Using a multi-meter, check continuity between connector X-ECC6B pin 1 and connector X-CN4A 25. A.

If there is no continuity, there is an open wire condition on wire 567 (White) between connector X-ECC6B pin 1 and connector X-CN4A 25. Repair or replace the wire.

B.

If there is continuity, continue with step 4

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC6A pin 1 and connector X-UJML pin 2. A.

If there is no continuity, there is an open wire condition on wire 567 (White) between connector X-ECC6A pin 1 and connector X-UJML pin 2. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC6B and X-ECC6A are not making a good connection at pin 1. Repair the connector.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-UJML pin 2, or connector X-CN4A pin 25 and ground. A.

If there is no continuity, continue with step 7. 84522361 15/06/2011

A.50.A / 276

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

10.

11.

12.

13.

If there is continuity, there is a short to ground condition on wire 567 (White) between connector X-UJML pin 2 and connector X-CN4A pin 25. Continue with step 6.

Locate the short to ground. Disconnect connector X-ECC6A from connector X-ECC6B. Using a multi-meter, check for continuity between connector X-ECC6B pin 1, or connector X-CN4A pin 25 and ground. A.

If there is no continuity, there is a short to ground on wire 567 (White) between connector X-UJML pin 2 and X-ECC6A pin 1. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 567 (White) between connector X-ECC6B pin 1 and connector X-CN4A pin 25. Repair or replace the shorted wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-UJML pin 2, or connector X-CN4A pin 25 and ground. A.

If there is no voltage, continue with step 9.

B.

If there is voltage, there is a short to high source on wire 567 (White) between connector X-UJML pin 2 and connector X-CN4A pin 25. Continue with step 8.

Locate the short to high. Disconnect connector X-ECC6A from X-ECC6B. Using a multi-meter, check for voltage between connector X-UJML pin 2 and ground. A.

If there is no voltage, there is a short to high source on wire 567 (White) between connector X-ECC6B pin 1 and connector X-CN4A pin 25. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 567 (White) between connector X-UJML pin 2 and connector X-ECC6A pin 1. Repair or replace the wire.

Check for proper resistance in the LEFT HAND CONTROL HANDLE. Using a multi-meter to check for resistance between LEFT HAND CONTROL HANDLE pins 2 and 4. A.

If resistance is normal, continue with step 10.

B.

If resistance is infinite, the LEFT HAND CONTROL HANDLE has developed an open. Replace the LH JOYSTICK.

C.

If resistance is 0 Ω, the LEFT HAND CONTROL HANDLE has shorted internally. Replace the LEFT HAND CONTROL HANDLE.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-UJML pin 4 and ground. A.

If there is continuity, continue with step 11.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 25, 23, 19, 2 and 1 to troubleshoot and isolate the faulty wire.

Check for proper operation of the LEFT HAND CONTROL HANDLE. Reconnect connector X-UJML to the LEFT HAND CONTROL HANDLE. Disconnect connector X-ECC6B from connector X-ECC6A. Using a multi-meter, check for voltage between connector X-ECC6A pin 1 and ground. A.

If voltage is greater than 4.8 V, the LEFT HAND CONTROL HANDLE has failed. Replace the LEFT HAND CONTROL HANDLE.

B.

If voltage is less than 4.8 V, continue with step 12.

Check for proper operation of the UCM. Reconnect connector X-CN4A to the UCM. Using a multi-meter, check for voltage between connector X-ECC6B pin 1 and ground. A.

If voltage is greater than 4.8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 4.8 V, continue with step 13.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN4A-25 and CN1A-1. A.

If resistance is normal, continue with step 14. 84522361 15/06/2011

A.50.A / 277

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

14.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. 0.2Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 278

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5202- L joystick L-R axis - Pin B STP / STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5202 has an error priority of Amber. In ISO pattern, Limp Home Ground Drive operation mode is enabled with Diagnostic Trouble Code 5202. In H-Pattern, Limp Home Implement operation mode is enabled with Diagnostic Trouble Code 5202. Cause: UCM has sensed that the 5 V signal has failed. (The fault is only activated when Ignition is On and pin voltage falls out of the range of 0.2 V to 4.8 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Open wire in circuit.

3.

Failure of LEFT HAND CONTROL HANDLE.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5202 - L joystick L-R axis - Pin B STP / STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 14.

Check for open circuit. Disconnect connector X-UJML from the LEFT HAND CONTROL HANDLE. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check continuity between connector X-UJML pin 8 and connector X-CN2B pin 14. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 562 (Green) between connector X-UJML pin 8 and connector X-CN2B pin 14. Continue with step 3.

Locate the open circuit. Disconnect connector X-ECC5B from X-ECC5A. Using a multi-meter, check continuity between connector X-ECC5B pin 11 and connector X-CN2B pin 14. A.

If there is no continuity, there is an open wire condition on wire 562 (Green) between connector X-ECC5B pin 11 and connector X-CN2B pin 14. Repair or replace the wire.

B.

If there is continuity, continue with step 4

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC5A pin 11 and connector X-UJML pin 8. A.

If there is no continuity, there is an open wire condition on wire 562 (Green) between connector X-ECC5A pin 11 and connector X-UJML pin 8. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC5B and X-ECC5A are not making a good connection at pin 11. Repair the connector.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-UJML pin 8, or connector X-CN2B pin 14 and ground. A.

If there is no continuity, continue with step 7. 84522361 15/06/2011

A.50.A / 279

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

10.

11.

12.

13.

If there is continuity, there is a short to ground condition on wire 562 (Green) between connector X-UJML pin 8 and connector X-CN2B pin 14. Continue with step 6.

Locate the short to ground. Disconnect connector X-ECC5A from connector X-ECC5B. Using a multi-meter, check for continuity between connector X-ECC5B pin 11, or connector X-CN2B pin 14 and ground. A.

If there is no continuity, there is a short to ground on wire 562 (Green) between connector X-UJML pin 8 and X-ECC5A pin 11. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 562 (Green) between connector X-ECC5B pin 11 and connector X-CN2B pin 14. Repair or replace the shorted wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-UJML pin 8, or connector X-CN2B pin 14 and ground. A.

If there is no voltage, continue with step 9.

B.

If there is voltage, there is a short to high source on wire 562 (Green) between connector X-UJML pin 8 and connector X-CN2B pin 14. Continue with step 8.

Locate the short to high. Disconnect connector X-ECC5A from X-ECC5B. Using a multi-meter, check for voltage between connector X-UJML pin 8 and ground. A.

If there is no voltage, there is a short to high source on wire 562 (Green) between connector X-ECC5B pin 11 and connector X-CN2B pin 14. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 562 (Green) between connector X-UJML pin 8 and connector X-ECC5A pin 11. Repair or replace the wire.

Check for proper resistance in the LEFT HAND CONTROL HANDLE. Using a multi-meter to check for resistance between LEFT HAND CONTROL HANDLE pins 8 and 10. A.

If resistance is normal, continue with step 10.

B.

If resistance is infinite, the LEFT HAND CONTROL HANDLE has developed an open. Replace the LEFT HAND CONTROL HANDLE.

C.

If resistance is 0 Ω, the LEFT HAND CONTROL HANDLE has shorted internally. Replace the LEFT HAND CONTROL HANDLE.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-UJML pin 10 and ground. A.

If there is continuity, continue with step 11.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 25, 23, 19, 2 and 1 to troubleshoot and isolate the faulty wire.

Check for proper operation of the LEFT HAND CONTROL HANDLE. Reconnect connector X-UJML to the LEFT HAND CONTROL HANDLE. Disconnect connector X-ECC5B from connector X-ECC5A. Using a multi-meter, check for voltage between connector X-ECC5A pin 11 and ground. A.

If voltage is greater than 4.8 V, the LEFT HAND CONTROL HANDLE has failed. Replace the LEFT HAND CONTROL HANDLE.

B.

If voltage is less than 4.8 V, continue with step 12.

Check for proper operation of the UCM. Reconnect connector X-CN2B to the UCM. Using a multi-meter, check for voltage between connector X-ECC5B pin 11 and ground. A.

If voltage is greater than 4.8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 4.8 V, continue with step 13.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2B-14 and CN1A-1. A.

If resistance is normal, continue with step 14. 84522361 15/06/2011

A.50.A / 280

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

14.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19)

84522361 15/06/2011

A.50.A / 281

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5204-L joystick L-R axis - in-range fault L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5204 has an error priority of Red. In ISO Pattern, Ground Drive operating mode is disabled with Diagnostic Trouble Code 5204. In H-Pattern, Disable Boom operating mode is enabled with Diagnostic Trouble Code 5204. Cause: UCM has sensed that the LEFT HAND CONTROL HANDLE has failed. (The fault is only activated when Ignition is On and the sum of the Left Hand Joystick output voltages falls out of the range of 4.8 V to 5.2 V.) Possible failure modes: 1.

Failure of the LEFT HAND CONTROL HANDLE

2.

Open or shorted wire in circuit.

3.

Failure of the UCM.

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 5204 - L joystick L-R axis - in-range fault is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check Instrument Cluster for other Trouble Codes. A.

If the other Trouble Codes are active, follow the procedure for those first.

B.

If the no other Trouble Codes are active, the LEFT HAND CONTROL HANDLE has failed. Replace the LEFT HAND CONTROL HANDLE.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23)

84522361 15/06/2011

A.50.A / 282

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5211- L joy F-B axis - Pin A STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5211 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 5211. Cause: UCM has sensed that the Left Joystick F-B 5 V signal has failed low. (The fault is only activated when Engine is On and voltage is less than 0.2 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Left Hand Control Handle.

3.

Open wire in circuit.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5211 - L joy F-B axis - Pin A STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 9.

Check for open circuit. Disconnect connector X-UJML from the LEFT HAND CONTROL HANDLE. Disconnect connector X-CN4A from the UCM. Using a multi-meter, check continuity between connector X-UJML pin 3 and connector X-CN4A pin 18. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 569 (White) between connector X-UJML pin 3 and connector X-CN4A pin 18. Continue with step 3.

Locate the open circuit. Disconnect connector X-ECC6A from X-ECC6B. Using a multi-meter, check continuity between connector X-ECC6B pin 2 and connector X-CN4A pin 18. A.

If there is no continuity, there is an open wire condition on wire 569 (White) between connector X-ECC6B pin 2 and connector X-CN4A pin 18. Repair or replace the wire.

B.

If there is continuity, there is an open wire condition on wire 569 (White) between connector X-ECC6A pin 2 and connector X-UJML pin 3, or connectors X-ECC6A and X-ECC6B are not making a good connection at pin 2. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-UJML pin 3, or connector X-CN4A pin 18 and ground. A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 569 (White) between connector X-UJML pin 3 and connector X-CN4A pin 18. Continue with step 5.

Locate the short to ground. Disconnect connector X-ECC6A from connector X-ECC6B. Using a multi-meter, check for continuity between connector X-ECC6B pin 2, or connector X-CN4A pin 18 and ground. A.

If there is no continuity, there is a short to ground on wire 569 (White) between connector X-UJML pin 3 and X-ECC6A pin 2. Repair or replace the shorted wire. 84522361 15/06/2011

A.50.A / 283

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

If there is continuity, there is a short to ground condition on wire 569 (White) between connector X-ECC6B pin 2 and connector X-CN4A pin 18. Repair or replace the shorted wire.

Check for proper resistance in the LEFT HAND CONTROL HANDLE. Using a multi-meter to check for resistance between LEFT HAND CONTROL HANDLE pins 9 and 10. A.

If resistance is normal, continue with step 7.

B.

If resistance is infinite, the LEFT HAND CONTROL HANDLE has developed an open. Replace the LEFT HAND CONTROL HANDLE.

C.

If resistance is 0 Ω, the LEFT HAND CONTROL HANDLE has shorted internally. Replace the LEFT HAND CONTROL HANDLE.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-UJML pin 10 and ground. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 23, 19, 25 and 1 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN4A-18 and CN1A-1. A.

If resistance is normal, continue with step 9.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19)

84522361 15/06/2011

A.50.A / 284

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5212- L joy F-B axis - Pin A STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5212 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 5212. Cause: UCM has sensed that the 5 V signal has failed high. (The fault is only activated when Ignition is On and Voltage is > 4.8 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Left Hand Control Module.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5212 - L joy F-B axis - Pin A STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for short to high. Disconnect connector X-UJML from the LH JOYSTICK. Disconnect connector X-CN4A from the UCM. Using a multi-meter, check for voltage between connector X-UJML pin 3, or connector X-CN4A pin 18 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 569 (White) between connector X-UJML pin 3 and connector X-CN4A pin 18. Continue with step 3.

Locate the short to high. Disconnect connector X-ECC6A from X-ECC6B. Using a multi-meter, check for voltage between connector X-UJML pin 3 and ground. A.

If there is no voltage, there is a short to high source on wire 569 (White) between connector X-ECC6B pin 2 and connector X-CN4A pin 18. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 569 (White) between connector X-UJML pin 3 and connector X-ECC6A pin 2. Repair or replace the wire.

Check for proper operation of the LH JOYSTICK. Reconnect connector X-UJML to the LH JOYSTICK. Disconnect connector X-ECC6B from connector X-ECC6A. Using a multi-meter, check for voltage between connector X-ECC6A pin 2 and ground. A.

If voltage is greater than 4.8 V, the LH JOYSTICK has failed. Replace the LH JOYSTICK.

B.

If voltage is less than 4.8 V, continue with step 5.

Check for proper operation of the UCM. Reconnect connector X-CN4A to the UCM. Using a multi-meter, check for voltage between connector X-ECC6B pin 2 and ground. A.

If voltage is greater than 4.8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 4.8 V, continue with step 6. 84522361 15/06/2011

A.50.A / 285

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 286

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5214-L joy F-B axis - Pin B STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5214 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 5214. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Engine is On and Voltage falls less than 0.2 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Left Hand Control Handle.

3.

Open wire in circuit.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5214 - L joy F-B axis - Pin B STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 9.

Check for open circuit. Disconnect connector X-UJML from the LEFT HAND CONTROL HANDLE. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check continuity between connector X-UJML pin 9 and connector X-CN2B pin 31. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 568 (Green) between connector X-UJML pin 9 and connector X-CN2B pin 31. Continue with step 3.

Locate the open circuit. Disconnect connector X-ECC5A from X-ECC5B. Using a multi-meter, check continuity between connector X-ECC5B pin 12 and connector X-CN2B pin 31. A.

If there is no continuity, there is an open wire condition on wire 568 (Green) between connector X-ECC5B pin 12 and connector X-CN2B pin 31. Repair or replace the wire.

B.

If there is continuity, there is an open wire condition on wire 568 (Green) between connector X-ECC5A pin 12 and connector X-UJML pin 9, or connectors X-ECC5A and X-ECC5B are not making a good connection at pin 12. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-UJML pin 9, or connector X-CN2B pin 31 and ground. A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 568 (Green) between connector X-UJML pin 9 and connector X-CN2B pin 31. Continue with step 5.

Locate the short to ground. Disconnect connector X-ECC5A from connector X-ECC5B. Using a multi-meter, check for continuity between connector X-ECC5B pin 12, or connector X-CN2B pin 31 and ground. A.

If there is no continuity, there is a short to ground on wire 568 (Green) between connector X-UJML pin 9 and X-ECC5A pin 12. Repair or replace the shorted wire. 84522361 15/06/2011

A.50.A / 287

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

If there is continuity, there is a short to ground condition on wire 568 (Green) between connector X-ECC5B pin 12 and connector X-CN2B pin 31. Repair or replace the shorted wire.

Check for proper resistance in the LEFT HAND CONTROL HANDLE. Using a multi-meter to check for resistance between LEFT HAND CONTROL HANDLE pins 9 and 10. A.

If resistance is normal, continue with step 7.

B.

If resistance is infinite, the LEFT HAND CONTROL HANDLE has developed an open. Replace the LEFT HAND CONTROL HANDLE.

C.

If resistance is 0 Ω, the LEFT HAND CONTROL HANDLE has shorted internally. Replace the LEFT HAND CONTROL HANDLE.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-UJML pin 10 and ground. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 23, 19, 25 and 1 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2B-18 and CN1A-1. A.

If resistance is normal, continue with step 9.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19)

84522361 15/06/2011

A.50.A / 288

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5215- L joy F-B axis - Pin B STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5215 has an error priority of Amber. Limp Home Ground Drive operating mode is enabled with Diagnostic Trouble Code 5215. Cause: UCM has sensed that the 5 V signal has failed high. (The fault is only activated when Ignition is On and Voltage is > 4.8 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Left Hand Control Module.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5215 - L joy F-B axis - Pin B STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for short to high. Disconnect connector X-UJML from the LH JOYSTICK. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check for voltage between connector X-UJML pin 9, or connector X-CN2B pin 31 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 568 (Green) between connector X-UJML pin 9 and connector X-CN2B pin 31. Continue with step 3.

Locate the short to high. Disconnect connector X-ECC5A from X-ECC5B. Using a multi-meter, check for voltage between connector X-UJML pin 9 and ground. A.

If there is no voltage, there is a short to high source on wire 568 (Green) between connector X-ECC5B pin 12 and connector X-CN2B pin 31. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 568 (Green) between connector X-UJML pin 9 and connector X-ECC5A pin 12. Repair or replace the wire.

Check for proper operation of the LH JOYSTICK. Reconnect connector X-UJML to the LH JOYSTICK. Disconnect connector X-ECC5B from connector X-ECC5A. Using a multi-meter, check for voltage between connector X-ECC5A pin 12 and ground. A.

If voltage is greater than 4.8 V, the LH JOYSTICK has failed. Replace the LH JOYSTICK.

B.

If voltage is less than 4.8 V, continue with step 5.

Check for proper operation of the UCM. Reconnect connector X-CN2B to the UCM. Using a multi-meter, check for voltage between connector X-ECC5B pin 12 and ground. A.

If voltage is greater than 4.8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 4.8 V, continue with step 6. 84522361 15/06/2011

A.50.A / 289

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 290

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5217- L joy F-B axis - in-range fault L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5217 has an error priority of Red. Ground Drive operating mode is disabled with Diagnostic Trouble Code 5217. Cause: UCM has sensed that the LEFT HAND CONTROL HANDLE has failed. (The fault is only activated when Engine is on and the sum of the Left Hand Handle output voltages falls out of the range of 4.8 V to 5.2 V.) Possible failure modes: 1.

Failure of the LEFT HAND CONTROL HANDLE

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 5217 - L joy F-B axis - in-range fault is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check Instrument Cluster for other Trouble Codes. A.

If the other Trouble Codes are active, follow the procedure for those first.

B.

If the no other Trouble Codes are active, the LEFT HAND CONTROL HANDLE has failed. Replace the LEFT HAND CONTROL HANDLE.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23)

84522361 15/06/2011

A.50.A / 291

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5221- Loader Arm Valve (Directional) - Solenoid Raise A Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5221 has an error priority of Red. Disable Boom is enabled with Diagnostic Trouble Code 5221. Cause: UCM has sent a signal to the Boom Valve Solenoid to energize, but the UCM does not sense proper current flow. (The fault is only activated when Hydraulics are Enabled and current from pin A is abnormal..) Possible failure modes: 1.

Loader Valve Extend solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5221 - Loader Arm Valve (Directional) - Solenoid Raise A Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for open circuit. Disconnect connector X-28 from the LOADER VALVE EXTEND SOLENOID. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check continuity between connector X-28 pin 1 and connector X-CN3B pin 6. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 513 (White) between connector X-28 pin 1 and connector X-CN3B pin 6. Continue with step 3.

Locate the open circuit. Disconnect connector X-88 from connector X-10. Using a multi-meter, check continuity between connector X-10 pin 7 and connector X-CN3B pin 6. A.

If there is no continuity, there is an open wire condition on wire 513 (White) between connector X-10 pin 7 and connector X-CN3B pin 6. Repair or replace the wire.

B.

If there is continuity, there is an open wire condition on wire 513 (White) between connector X-88 pin 7 and connector X-28 pin 1, or connectors X-88 and X-10 are not making a good connection at pin 7. Repair or replace the wire.

Check for proper resistance in the LOADER VALVE EXTEND SOLENOID. Using a multi-meter to check for resistance between LOADER VALVE EXTEND SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the LOADER VALVE EXTEND SOLENOID has developed an open. Replace the LOADER VALVE EXTEND SOLENOID.

C.

If resistance is 0 Ω, the LOADER VALVE EXTEND SOLENOID has shorted internally. Replace the LOADER VALVE EXTEND SOLENOID.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-28 pin 2 and ground. 84522361 15/06/2011

A.50.A / 292

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

A.

If there is continuity, continue with step 6.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 25, and 24 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-6 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 293

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5222- Loader Arm Valve (Directional) - Solenoid Raise A Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5222 has an error priority of Red. Disable Boom operation mode is enabled with Diagnostic Trouble Code 5222. Cause: The UCM has sent a signal to the Loader Valve Extend Solenoid to energize, but there is no voltage detected. (The fault is only activated when Hydraulics are Enabled and Aux Override is disabled and Loader Lock is Off and solenoid output pin current is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Loader Valve Extend Solenoid has failed.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5222 - Loader Arm Valve (Directional) - Solenoid Raise A Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for a short to ground. Disconnect connector X-28 from the LOADER VALVE EXTEND SOLENOID. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check for continuity between connector X-28 pin 1, or connector X-CN3B pin 6 and ground. A.

If there is no continuity, continue with step 4.

B.

If there is continuity, there is a short to ground condition on wire 513 (White) between connector X-28 pin 1 and connector X-CN3B pin 6. Continue with step 3.

Locate the short to ground. Disconnect connector X-88 from connector X-10. Using a multi-meter, check for continuity between connector X-10 pin 7, or connector X-CN3B pin 6 and ground. A.

If there is no continuity, there is a short to ground on wire 513 (White) between connector X-28 pin 1 and X-88 pin 7. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 513 (White) between connector X-10 pin 7 and connector X-CN3B pin 6. Repair or replace the shorted wire.

Check for proper resistance in the LOADER VALVE EXTEND SOLENOID. Using a multi-meter to check for resistance between LOADER VALVE EXTEND SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the LOADER VALVE EXTEND SOLENOID has developed an open. Replace the LOADER VALVE EXTEND SOLENOID.

C.

If resistance is 0 Ω, the LOADER VALVE EXTEND SOLENOID has shorted internally. Replace the LOADER VALVE EXTEND SOLENOID.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-6 and CN1A-1. 84522361 15/06/2011

A.50.A / 294

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

A.

If resistance is normal, continue with step 6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. If multiple Diagnostic Trouble Codes are active, troubleshoot another Diagnostic Trouble Code. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 295

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5231- Loader Arm Valve (Directional) - Solenoid Lower B Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5231 has an error priority of Red. Disable Boom operation mode is enabled with Diagnostic Trouble Code 5231. Cause: UCM has sent a signal to the Boom Valve Solenoid to energize, but the UCM does not sense proper current flow. (The fault is only activated when Hydraulics are Enabled and current from pin B is abnormal.) Possible failure modes: 1.

Loader Valve Retract solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5231 - Loader Arm Valve (Directional) - Solenoid Lower B Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for open circuit. Disconnect connector X-27 from the LOADER VALVE RETRACT SOLENOID. Disconnect connector X-CN3A from the UCM. Using a multi-meter, check continuity between connector X-27 pin 1 and connector X-CN3A pin 22. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 512 (White) between connector X-27 pin 1 and connector X-CN3A pin 22. Continue with step 3.

Locate the open circuit. Disconnect connector X-88 from connector X-10. Using a multi-meter, check continuity between connector X-10 pin 5 and connector X-CN3A pin 22. A.

If there is no continuity, there is an open wire condition on wire 512 (White) between connector X-10 pin 5 and connector X-CN3A pin 22. Repair or replace the wire.

B.

If there is continuity, there is an open wire condition on wire 512 (White) between connector X-88 pin 5 and connector X-27 pin 1, or connectors X-88 and X-10 are not making a good connection at pin 5. Repair or replace the wire.

Check for proper resistance in the LOADER VALVE RETRACT SOLENOID. Using a multi-meter to check for resistance between LOADER VALVE RETRACT SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the LOADER VALVE RETRACT SOLENOID has developed an open. Replace the LOADER VALVE RETRACT SOLENOID.

C.

If resistance is 0 Ω, the LOADER VALVE RETRACT SOLENOID has shorted internally. Replace the LOADER VALVE RETRACT SOLENOID.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-27 pin 2 and ground. 84522361 15/06/2011

A.50.A / 296

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

A.

If there is continuity, continue with step 6.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 25, and 24 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3A-22 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 297

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5232- Loader Arm Valve (Directional) - Solenoid Lower B Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5232 has an error priority of Red. Disable Boom operating mode is enabled with Diagnostic Trouble Code 5232. Cause: The UCM has sent a signal to the Loader Valve Retract Solenoid to energize, but there is no voltage detected. (The fault is only activated when Hydraulics are Enabled and Aux Override is disabled and Loader Lock is Off and solenoid output pin current is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Loader Valve Retract Solenoid has failed.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 5232 - Loader Arm Valve (Directional) - Solenoid Lower B Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for a short to ground. Disconnect connector X-27 from the LOADER VALVE RETRACT SOLENOID. Disconnect connector X-CN3A from the UCM. Using a multi-meter, check for continuity between connector X-27 pin 1, or connector X-CN3A pin 22 and ground. A.

If there is no continuity, continue with step 4.

B.

If there is continuity, there is a short to ground condition on wire 512 (White) between connector X-27 pin 1 and connector X-CN3A pin 22. Continue with step 3.

Locate the short to ground. Disconnect connector X-88 from connector X-10. Using a multi-meter, check for continuity between connector X-10 pin 5, or connector X-CN3A pin 22 and ground. A.

If there is no continuity, there is a short to ground on wire 512 (White) between connector X-27 pin 1 and X-88 pin 5. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 512 (White) between connector X-10 pin 5 and connector X-CN3A pin 22. Repair or replace the shorted wire.

Check for proper resistance in the LOADER VALVE RETRACT SOLENOID. Using a multi-meter to check for resistance between LOADER VALVE RETRACT SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the LOADER VALVE RETRACT SOLENOID has developed an open. Replace the LOADER VALVE RETRACT SOLENOID.

C.

If resistance is 0 Ω, the LOADER VALVE RETRACT SOLENOID has shorted internally. Replace the LOADER VALVE RETRACT SOLENOID.

84522361 15/06/2011

A.50.A / 298

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5.

6.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3A-22 and CN1A-1. A.

If resistance is normal, continue with step 6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. If multiple Diagnostic Trouble Codes are active, troubleshoot another Diagnostic Trouble Code. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 299

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5241- Boom Valve (Directional) - Common Solenoid (C) Return STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5241 has an error priority of Red. Disable Boom operating mode is enabled with Diagnostic Trouble Code 5241. Cause: UCM has sensed higher than normal voltage on the Boom Valve Solenoids ground line. (The fault is only activated when Hydraulics are disabled, ignition is on and solenoid voltage is greater than 5 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5241 - Boom Valve (Directional) Common Solenoid (C) Return STP is present. A.

If the fault is present, continue with step 2.

B.

If the fault is not present, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high. Disconnect connector X-CN3A from the UCM. Disconnect connector X-CN3B from the UCM. Disconnect connector X-CN2B from the UCM. Disconnect connector X-27 from the LOADER VALVE RETRACT. Disconnect connector X-28 from the LOADER VALVE EXTEND. Using a multi-meter, check for voltage between connector X-27 pin 1 and ground. A.

If there is no voltage, continue with step 3.

B.

If there is voltage, there is a short to high source on wire 512 (White) between connector X-27 pin 1 and connector X-CN3A pin 22. Repair or replace the wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-28 pin 1 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 513 (White) between connector X-CN3B pin 6 and connector X-28 pin 1. Repair or replace the wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-27 pin 2 and ground. A.

If there is no voltage, continue with step 5.

B.

If there is voltage, there is a short to high source on wire 1019/1080 (Black) between connector X-CN2B pin 7 and connector X-27 pin 2, or on wire 1081 (Black) between SPLICE 155 and connector X-28 pin 2. Repair or replace the wire.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

84522361 15/06/2011

A.50.A / 300

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 301

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5242- Loader Arm Valve (Directional) - Loader Arm Solenoids STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5242 has an error priority of Red. Disable Boom is enabled with Diagnostic Trouble Code 5242. Cause: UCM has sensed that the solenoid return voltage is low. (The fault is only activated when Hydraulics are disabled and solenoid return voltage is low.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of UCM.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 5242 - Loader Arm Valve (Directional) - Loader Arm Solenoids STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for a short to ground. Disconnect connector X-27 from the LOADER VALVE EXTEND. Disconnect connector X-28 from the LOADER VALVE RETRACT. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check for continuity between connector X-27 pin 2 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 1019/1080 (White) between connector X-CN2B pin 7 and connector X-27 pin 2, or on wire 1081 (White) between SPLICE 155 and connector X-28 pin 2. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2B-7 and CN1A-1. A.

If resistance is normal, continue with step 4.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) 84522361 15/06/2011

A.50.A / 302

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 303

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5243- Boom Valve (Directional) - Common Solenoid (C) Return OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5243 has an error priority of Red. Disable Boom operating mode is enabled with Diagnostic Trouble Code 5243. Cause: UCM has sensed abnormal current on the Boom Valve Solenoids ground line. (The fault is only activated when Hydraulics are enabled and Boom Valve solenoid ground line current is abnormal.) Possible failure modes: 1.

Open wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

6.

Use the machine to recreate conditions for error. Use the EST to verify 5243 - Boom Valve (Directional) Common Solenoid (C) Return OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for an open wire condition. Disconnect connector X-CN2B from the UCM. Disconnect connector X-27 from the LOADER VALVE RETRACT SOLENOID. Disconnect connector X-28 from the LOADER VALVE EXTEND SOLENOID. Using a multi-meter, check for continuity between connector X-CN2B pin 7 and connector X-27 pin 2. A.

If there is no continuity, there is an open wire condition on wire 1019 (Blue) between X-CN2B pin 7 and SPLICE 155. Continue with step 3.

B.

If there is continuity, continue with step 5.

Check for an open wire condition. Disconnect connector X-88 from connector X-10. Using a multi-meter, check for continuity between X-88 pin 6 and X-27 pin 2. A.

If there is no continuity, there is an open wire condition on wire 1019 (Blue) between X-88 pin 6 and SPLICE 155. Repair or replace wire.

B.

If there is continuity, continue with step 4.

Check for an open wire condition. Using a multi-meter, check for continuity between connector X-10 pin 6 and connector X-CN2B pin 7. A.

If there is no continuity, there is an open wire condition on wire 1019 (Blue) between X-10 pin 6 and connector X-CN2B pin 7. Repair or replace wire.

B.

If there is continuity, connectors X-10 and X-88 are not making a good connection at pin 6. Repair the connector.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2B-7 and CN1A-1. A.

If resistance is normal, continue with step 6.

B.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent 84522361 15/06/2011

A.50.A / 304

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 305

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5251- Loader Bucket Valve (Directional) - Solenoid rollback (A) Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5251 has an error priority of Red. Disable Bucket operating mode is enabled with Diagnostic Trouble Code 5251. Cause: UCM has sensed abnormal solenoid current flow. (The fault is only activated when Hydraulics are Enabled and current from pin A is abnormal.) Possible failure modes: 1.

Bucket Valve solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5251 - Loader Bucket Valve (Directional) - Solenoid rollback (A) Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for open circuit. Disconnect connector X-25 from the BUCKET VALVE RETRACT SOLENOID. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check continuity between connector X-25 pin 1 and connector X-CN3B pin 17. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 510 (White) between connector X-25 pin 1 and connector X-CN3B pin 17. Continue with step 3.

Locate the open circuit. Disconnect connector X-88 from connector X-10. Using a multi-meter, check continuity between connector X-10 pin 1 and connector X-CN3B pin 17. A.

If there is no continuity, there is an open wire condition on wire 510 (White) between connector X-10 pin 1 and connector X-CN3B pin 17. Repair or replace the wire.

B.

If there is continuity, continue with step 4.

Locate the open circuit. Using a multi-meter, check continuity between connector X-88 pin 1 and connector X-25 pin 1. A.

If there is no continuity, there is an open wire condition on wire 510 (White) between connector X-88 pin 1 and connector X-25 pin 1. Repair or replace the wire.

B.

If there is continuity, connectors X-10 and X-88 are not making a good connection at pin 1. Repair the connector.

Check for proper resistance in the BUCKET VALVE RETRACT SOLENOID. Using a multi-meter to check for resistance between BUCKET VALVE RETRACT SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 6.

84522361 15/06/2011

A.50.A / 306

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

B.

If resistance is infinite, the BUCKET VALVE RETRACT SOLENOID has developed an open. Replace the BUCKET VALVE RETRACT SOLENOID.

C.

If resistance is 0 Ω, the BUCKET VALVE RETRACT SOLENOID has shorted internally. Replace the BUCKET VALVE RETRACT SOLENOID.

Check for proper resistance in the ground circuit. Disconnect connector X-88 from connector X-10. Using a multi-meter, check for continuity between connector X-25 pin 2 and ground. A.

If there is continuity, continue with step 7.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 25 and 24 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all eight connectors. Using a multi-meter, check for resistance between UCM pins CN3B-17 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 307

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5252- Loader Bucket Valve (Directional) - Solenoid rollback (A) Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5252 has an error priority of Red. Disable Bucket operating mode is enabled with Diagnostic Trouble Code 5252. Cause: The UCM has sent a signal to the Bucket Valve Retract Solenoid to energize, but there is no voltage detected. (The fault is only activated when Hydraulics are Enabled and solenoid output pin current is greater than 3 A.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Bucket Valve Solenoid has failed.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5252 - Loader Bucket Valve (Directional) - Solenoid rollback (A) Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for a short to ground. Disconnect connector X-CN3B from the UCM. Disconnect connector X-25 from the BUCKET VALVE RETRACT SOLENOID. Using a multi-meter, check for continuity between connector X-25 pin 1, or connector X-CN3B pin 17 and ground. A.

If there is no continuity, continue with step 4.

B.

If there is continuity, there is a short to ground condition on wire 510 (White) between connector X-25 pin 1 and connector X-CN3B pin 17. Continue with step 3.

Locate the short to ground. Disconnect connector X-88 from connector X-10. Using a multi-meter, check for continuity between connector X-10 pin 1, or connector X-CN3B pin 17 and ground. A.

If there is no continuity, there is a short to ground on wire 510 (White) between connector X-25 pin 1 and X-88 pin 1. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 510 (White) between connector X-10 pin 1 and connector X-CN3B pin 17. Repair or replace the shorted wire.

Check for proper resistance in the BUCKET VALVE RETRACT SOLENOID. Using a multi-meter to check for resistance between BUCKET VALVE RETRACT SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the BUCKET VALVE RETRACT SOLENOID has developed an open. Replace the BUCKET VALVE RETRACT SOLENOID.

C.

If resistance is 0 Ω, the BUCKET VALVE RETRACT SOLENOID has shorted internally. Replace the BUCKET VALVE RETRACT SOLENOID.

Check for proper resistance of the UCM. Completely power down the UCM by removing all eight connectors. Using a multi-meter, check for resistance between UCM pins CN3B-17 and CN1A-1. 84522361 15/06/2011

A.50.A / 308

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

A.

If resistance is normal, continue with step 6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. If multiple Diagnostic Trouble Codes are active, troubleshoot another Diagnostic Trouble Code. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 309

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5261- Bucket Valve (Directional) - Solenoid dump (B) Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5261 has an error priority of Red. Disable Bucket operating mode is enabled with Diagnostic Trouble Code 5261. Cause: UCM has sensed abnormal solenoid current flow. (The fault is only activated when Hydraulics are Enabled and current from pin B is abnormal.) Possible failure modes: 1.

Bucket Valve solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5261 - Bucket Valve (Directional) Solenoid dump (B) Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for open circuit. Disconnect connector X-26 from the BUCKET VALVE EXTEND SOLENOID. Disconnect connector X-CN4A from the UCM. Using a multi-meter, check continuity between connector X-26 pin 1 and connector X-CN4A pin 19. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 511 (White) between connector X-26 pin 1 and connector X-CN4A pin 19. Continue with step 3.

Locate the open circuit. Disconnect connector X-88 from connector X-10. Using a multi-meter, check continuity between connector X-10 pin 3 and connector X-CN4A pin 19. A.

If there is no continuity, there is an open wire condition on wire 511 (White) between connector X-10 pin 3 and connector X-CN4A pin 19. Repair or replace the wire.

B.

If there is continuity, there is an open wire condition on wire 511 (White) between connector X-88 pin 3 and connector X-26 pin 1, or connectors X-88 and X-10 are not making a good connection at pin 3. Repair or replace the wire.

Check for proper resistance in the BUCKET VALVE EXTEND SOLENOID. Using a multi-meter to check for resistance between BUCKET VALVE EXTEND SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the BUCKET VALVE EXTEND SOLENOID has developed an open. Replace the BUCKET VALVE EXTEND SOLENOID.

C.

If resistance is 0 Ω, the BUCKET VALVE EXTEND SOLENOID has shorted internally. Replace the BUCKET VALVE EXTEND SOLENOID.

Check for proper resistance in the ground circuit. Using a multi-meter, check for continuity between connector X-26 pin 2 and ground. 84522361 15/06/2011

A.50.A / 310

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

A.

If there is continuity, continue with step 6.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 25, and 24 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all eight connectors. Using a multi-meter, check for resistance between UCM pins CN4A-19 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 311

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5262- Bucket Valve (Directional) - Solenoid dump (B) Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5262 has an error priority of Red. Disable Bucket operating mode is enabled with Diagnostic Trouble Code 5262. Cause: The UCM has sent a signal to the Bucket Valve Retract Solenoid to energize, but there is no voltage detected. (The fault is only activated when Hydraulics are Enabled and solenoid output pin current is greater than 3 A.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Bucket Valve Solenoid has failed.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5262 - Bucket Valve (Directional) Solenoid dump (B) Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for a short to ground. Disconnect connector X-CN4A from the UCM. Disconnect connector X-26 from the BUCKET VALVE EXTEND SOLENOID. Using a multi-meter, check for continuity between connector X-26 pin 1, or connector X-CN4A pin 19 and ground. A.

If there is no continuity, continue with step 4.

B.

If there is continuity, there is a short to ground condition on wire 511 (White) between connector X-26 pin 1 and connector X-CN4A pin 19. Continue with step 3.

Locate the short to ground. Disconnect connector X-88 from connector X-10. Using a multi-meter, check for continuity between connector X-10 pin 3, or connector X-CN4A pin 19 and ground. A.

If there is no continuity, there is a short to ground on wire 511 (White) between connector X-26 pin 1 and connector X-88 pin 3. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 511 (White) between connector X-10 pin 3 and connector X-CN4A pin 19. Repair or replace the shorted wire.

Check for proper resistance in the BUCKET VALVE EXTEND SOLENOID. Using a multi-meter to check for resistance between BUCKET VALVE EXTEND SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the BUCKET VALVE EXTEND SOLENOID has developed an open. Replace the BUCKET VALVE EXTEND SOLENOID.

C.

If resistance is 0 Ω, the BUCKET VALVE EXTEND SOLENOID has shorted internally. Replace the BUCKET VALVE EXTEND SOLENOID.

Check for proper resistance of the UCM. Completely power down the UCM by removing all eight connectors. Using a multi-meter, check for resistance between UCM pins CN4A-19 and CN1A-1. A.

If resistance is normal, continue with step 6. 84522361 15/06/2011

A.50.A / 312

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. If multiple Diagnostic Trouble Codes are active, troubleshoot another Diagnostic Trouble Code. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 313

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5271- Bucket Valve (Directional) - Common Solenoid (C) Return STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5271 has an error priority of Red. Disable Bucket operating mode is enabled with Diagnostic Trouble Code 5271. Cause: UCM has sensed higher than normal voltage on the Bucket Valve Solenoids ground line. (The fault is only activated when Hydraulics are disabled and voltage feedback is greater than 5 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5271 - Bucket Valve (Directional) Common Solenoid (C) Return STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high. Disconnect connector X-CN4A from the UCM. Disconnect connector X-CN3B from the UCM. Disconnect connector X-CN1A from the UCM. Disconnect connector X-25 from the BUCKET VALVE RETRACT. Disconnect connector X-26 from the BUCKET VALVE EXTEND. Using a multi-meter, check for voltage between connector X-25 pin 1 and ground. A.

If there is no voltage, continue with step 3.

B.

If there is voltage, there is a short to high source on wire 510 (White) between connector X-25 pin 1 and connector X-CN3B pin 17. Repair or replace the wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-26 pin 1 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 511 (White) between connector X-CN4A pin 19 and connector X-26 pin 1. Repair or replace the wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-25 pin 2 and ground. A.

If there is no voltage, continue with step 5.

B.

If there is voltage, there is a short to high source on wire 1018/1078 (Black) between connector X-CN1A pin 13 and connector X-25 pin 2, or on wire 1079 (Black) between SPLICE 154 and connector X-26 pin 2. Repair or replace the wire.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

84522361 15/06/2011

A.50.A / 314

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 315

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5272- Loader Bucket Valve (Directional) - Loader Bucket Solenoids STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5272 has an error priority of Red. Disable Bucket is enabled with Diagnostic Trouble Code 5272. Cause: UCM has sensed that the solenoid return voltage is low. (The fault is only activated when Hydraulics are disabled and solenoid return voltage is low.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of UCM.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 5272 - Loader Bucket Valve (Directional) - Loader Bucket Solenoids STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for a short to ground. Disconnect connector X-26 from the BUCKET VALVE EXTEND. Disconnect connector X-25 from the BUCKET VALVE RETRACT. Disconnect connector X-CN1A from the UCM. Using a multi-meter, check for continuity between connector X-25 pin 2 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 1018/1078 (Blue) between connector X-CN1A pin 13 and connector X-25 pin 2, or on wire 1079 (Blue) between SPLICE 154 and connector X-26 pin 2. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1A-13 and CN1A-1. A.

If resistance is normal, continue with step 4.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

84522361 15/06/2011

A.50.A / 316

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 317

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5273- Bucket Valve (Directional) - Common Solenoid (C) Return OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5273 has an error priority of Red. Disable Bucket operating mode is enabled with Diagnostic Trouble Code 5273. Cause: UCM has sensed abnormal current . (The fault is only activated when Hydraulics is enabled and Bucket Valve solenoid return line current is abnormal.) Possible failure modes: 1.

Open wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

6.

Use the machine to recreate conditions for error. Use the EST to verify 5273 - Bucket Valve (Directional) Common Solenoid (C) Return OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for open circuit. Disconnect connector X-25 from the BUCKET VALVE RETRACT SOLENOID. Disconnect connector X-26 from the BUCKET VALVE EXTEND SOLENOID. Disconnect connector X-CN1A from the UCM. Using a multi-meter, check continuity between connector X-25 pin 2 and connector X-CN1A pin 13. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 1018 (Blue) between SPLICE 154 and connector X-CN1A pin 13. Continue with step 3.

Locate the open circuit. Disconnect connector X-88 from connector X-10. Using a multi-meter, check continuity between connector X-10 pin 2 and connector X-CN1A pin 13. A.

If there is no continuity, there is an open wire condition on wire 1018 (Blue) between connector X-10 pin 2 and connector X-CN1A pin 13. Repair or replace the wire.

B.

If there is continuity, continue with step 4

Locate the open circuit. Using a multi-meter, check continuity between connector X-88 pin 2 and connector X-25 pin 2. A.

If there is no continuity, there is an open wire condition on wire 1018 (Blue) between SPLICE 154 and connector X-88 pin 2. Repair or replace the wire.

B.

If there is continuity, connectors X-88 and X-10 are not making a good connection at pin 2. Repair the connector.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pinsCN1A-13 and CN1A-1. A.

If resistance is normal, continue with step 6.

B.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent 84522361 15/06/2011

A.50.A / 318

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 319

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5281- Aux Valve (Directional) - Solenoid Forward (A) Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5281 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Aux operating mode is enabled with Diagnostic Trouble Code 5281. Cause: UCM has sensed improper Loader Auxiliary Valve solenoid current. (The fault is only activated when Hydraulics are enabled and solenoid supply current is incorrect.) Possible failure modes: 1.

Open wire in circuit.

2.

Failure of Proportional Aux Valve Extend solenoid.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5281 - Aux Valve (Directional) - Solenoid Forward (A) Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for open circuit. Disconnect connector X-24 from the PROPORTIONAL AUX VALVE EXTEND SOLENOID. Disconnect connector X-CN1B from the UCM. Using a multi-meter, check continuity between connector X-24 pin 1 and connector X-CN1B pin 33. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 514 (White) between connector X-24 pin 1 and connector X-CN1B pin 33. Continue with step 3.

Locate the open circuit. Disconnect connector X-10 from connector X-88. Using a multi-meter, check continuity between connector X-10 pin 12 and connector X-CN1B pin 33. A.

If there is no continuity, there is an open wire condition on wire 514 (White) between connector X-10 pin 12 and connector X-CN1B pin 33. Repair or replace the wire.

B.

If there is continuity, continue with step 4

Locate the open circuit. Using a multi-meter, check continuity between connector X-88 pin 12 and connector X-24 pin 1. A.

If there is no continuity, there is an open wire condition on wire 514 (White) between connector X-88 pin 12 and connector X-24 pin 1. Repair or replace the wire.

B.

If there is continuity, connectors X-10 and X-88 are not making a good connection at pin 12. Repair the connector.

Check for proper resistance in the PROPORTIONAL AUX VALVE EXTEND SOLENOID. Using a multi-meter to check for resistance between PROPORTIONAL AUX VALVE EXTEND SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 6. 84522361 15/06/2011

A.50.A / 320

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

B.

If resistance is infinite, the PROPORTIONAL AUX VALVE EXTEND SOLENOID has developed an open. Replace the PROPORTIONAL AUX VALVE EXTEND SOLENOID.

C.

If resistance is 0 Ω, the PROPORTIONAL AUX VALVE EXTEND SOLENOID has shorted internally. Replace the PROPORTIONAL AUX VALVE EXTEND SOLENOID.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-24 pin 2 and ground. A.

If there is continuity, continue with step 7.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 25, and 24 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-33 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25)

84522361 15/06/2011

A.50.A / 321

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5282- Aux Valve (Directional) - Solenoid Forward (A) Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5282 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Aux operating mode is enabled with Diagnostic Trouble Code 5282. Cause: UCM has sensed that the Proportional Aux Valve Extend solenoid has high output current. (The fault is only activated when Hydraulics are enabled and solenoid output pin current is greater than 3 A.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Proportional Aux Valve Extend solenoid.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5282 - Aux Valve (Directional) - Solenoid Forward (A) Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for a short to ground. Disconnect connector X-24 from the PROPORTIONAL AUX VALVE EXTEND SOLENOID. Disconnect connector X-CN1B from the UCM. Using a multi-meter, check for continuity between connector X-24 pin 1, or connector X-CN1B pin 33 and ground. A.

If there is no continuity, continue with step 4.

B.

If there is continuity, there is a short to ground condition on wire 514 (White) between connector X-24 pin 1 and connector X-CN1B pin 33. Continue with step 3.

Locate the short to ground. Disconnect connector X-10 from connector X-88. Using a multi-meter, check for continuity between connector X-10 pin 12, or connector X-CN1B pin 33 and ground. A.

If there is no continuity, there is a short to ground on wire 514 (White) between connector X-24 pin 1 and X-88 pin 12. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 514 (White) between connector X-10 pin 12 and connector X-CN1B pin 33. Repair or replace the shorted wire.

Check for proper resistance in the PROPORTIONAL AUX VALVE EXTEND SOLENOID. Using a multi-meter to check for resistance between PROPORTIONAL AUX VALVE EXTEND SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the PROPORTIONAL AUX VALVE EXTEND SOLENOID has developed an open. Replace the PROPORTIONAL AUX VALVE EXTEND SOLENOID.

C.

If resistance is 0 Ω, the PROPORTIONAL AUX VALVE EXTEND SOLENOID has shorted internally. Replace the PROPORTIONAL AUX VALVE EXTEND SOLENOID.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-33 and CN1A-1. 84522361 15/06/2011

A.50.A / 322

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

A.

If resistance is normal, continue with step 6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25)

84522361 15/06/2011

A.50.A / 323

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5291- Aux Valve (Directional) - Solenoid Reverse (B) Supply OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5291 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Aux operating mode is enabled with Diagnostic Trouble Code 5291. Cause: UCM has sensed improper Loader Auxiliary Valve solenoid current. (The fault is only activated when Hydraulics are enabled and solenoid supply current is incorrect.) Possible failure modes: 1.

Proportional Aux Valve Retract Solenoid has failed.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 5291 - Aux Valve (Directional) - Solenoid Reverse (B) Supply OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 7.

Check for open circuit. Disconnect connector X-29 from the PROPORTIONAL AUX VALVE RETRACT SOLENOID. Disconnect connector X-CN1A from the UCM. Using a multi-meter, check continuity between connector X-29 pin 1 and connector X-CN1A pin 24. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 515 (White) between connector X-29 pin 1 and connector X-CN1A pin 24. Continue with step 3.

Locate the open circuit. Disconnect connector X-88 from X-10. Using a multi-meter, check continuity between connector X-10 pin 10 and connector X-CN1A pin 24. A.

If there is no continuity, there is an open wire condition on wire 515 (White) between connector X-10 pin 10 and connector X-CN1A pin 24. Repair or replace the wire.

B.

If there is continuity, there is an open wire condition on wire 515 (White) between connector X-88 pin 10 and connector X-29 pin 1, or connectors X-88 and X-10 are not making a good connection at pin 10. Repair or replace the wire.

Check for proper resistance in the PROPORTIONAL AUX VALVE RETRACT SOLENOID. Using a multi-meter to check for resistance between PROPORTIONAL AUX VALVE RETRACT SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the PROPORTIONAL AUX VALVE RETRACT SOLENOID has developed an open. Replace the PROPORTIONAL AUX VALVE RETRACT SOLENOID.

C.

If resistance is 0 Ω, the PROPORTIONAL AUX VALVE RETRACT SOLENOID has shorted internally. Replace the PROPORTIONAL AUX VALVE RETRACT SOLENOID.

84522361 15/06/2011

A.50.A / 324

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5.

6.

7.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-29 pin 2 and ground. A.

If there is continuity, continue with step 6.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 25 and 24 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1A-24 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 325

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5292- Aux Valve (Directional) - Solenoid Reverse (B) Supply STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5292 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Auxiliary operating mode is enabled with Diagnostic Trouble Code 5292. Cause: The UCM has sent a signal to the Proportional Aux Valve Retract Solenoid to energize, but there is no voltage detected. (The fault is only activated when Hydraulics are Enabled and solenoid output pin current feedback is greater than 3 A.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Proportional Aux Valve Retract Solenoid has failed.

3.

UCM has an internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 5292 - Aux Valve (Directional) - Solenoid Reverse (B) Supply STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for a short to ground. Disconnect connector X-CN1A from the UCM. Disconnect connector X-29 from the PROPORTIONAL AUX VALVE RETRACT SOLENOID. Using a multi-meter, check for continuity between connector X-29 pin 1, or connector X-CN1A pin 24 and ground. A.

If there is no continuity, continue with step 4.

B.

If there is continuity, there is a short to ground condition on wire 515 (White) between connector X-29 pin 1 and connector X-CN1A pin 24. Continue with step 3.

Locate the short to ground. Disconnect connector X-88 from connector X-10. Using a multi-meter, check for continuity between connector X-10 pin 10, or connector X-CN1A pin 24 and ground. A.

If there is no continuity, there is a short to ground on wire 515 (White) between connector X-29 pin 1 and X-88 pin 10. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 515 (White) between connector X-10 pin 10 and connector X-CN1A pin 24. Repair or replace the shorted wire.

Check for proper resistance in the PROPORTIONAL AUX VALVE RETRACT SOLENOID. Using a multi-meter to check for resistance between PROPORTIONAL AUX VALVE RETRACT SOLENOID pins 1 and 2. A.

If resistance is normal, continue with step 5.

B.

If resistance is infinite, the PROPORTIONAL AUX VALVE RETRACT SOLENOID has developed an open. Replace the PROPORTIONAL AUX VALVE RETRACT SOLENOID.

C.

If resistance is 0 Ω, the PROPORTIONAL AUX VALVE RETRACT SOLENOID has shorted internally. Replace the PROPORTIONAL AUX VALVE RETRACT SOLENOID.

84522361 15/06/2011

A.50.A / 326

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5.

6.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1A-24 and CN1A-1. A.

If resistance is normal, continue with step 6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 327

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5309- Float Button - Float Button Timeout (30 sec) L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5309 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Loader Float is disabled with Diagnostic Trouble Code 5309. Cause: UCM has sensed that the signal has failed. (The fault is only activated when Ignition is On and Float button output is high for more than 30 s.) Possible failure modes: 1.

Failure of Float Button.

2.

Failure of Instrument Cluster.

3.

Failure of UCM.

Solution: 1.

2.

3.

Use the machine to recreate conditions for error. Use the EST to verify 5309 - Float Button - Float Button Timeout (30 sec) is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 3.

Check for proper resistance in the FLOAT BUTTON. Disconnect connector X-403 from the FLOAT BUTTON. Using a multi-meter, check for resistance between FLOAT BUTTON pins 13 and 14. A.

If resistance is infinite, the FLOAT BUTTON is not closed. Continue with step 3.

B.

If resistance is 0 Ω, the FLOAT BUTTON has shorted internally. Replace the FLOAT BUTTON.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19) harness - Electrical schematic frame 07 (A.30.A.88-C.20.E.07)

84522361 15/06/2011

A.50.A / 328

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5409- CAN Message Error - Aux Override Disabled due to Aux Override Button Timeout (30 sec) L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5409 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Aux Override is disabled with Diagnostic Trouble Code 5409. Cause: The Instrument Cluster has sensed an error with the Aux Override Button status. (The fault is activated when ignition is on and CAN message from AIC is high for more than 30 seconds. Possible failure modes: 1.

Failure of the Instrument Cluster.

Solution: 1.

Use the EST to verify 5409 - CAN Message Error - Aux Override Disabled due to Aux Override Button Timeout (30 sec) is active. A.

If the fault is active, erase it with the EST.

2. If the fault persists, it is an indication of an INSTRUMENT CLUSTER failure. Replace the INSTRUMENT CLUSTER. Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)

84522361 15/06/2011

A.50.A / 329

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5501- Loader Arm Spool Sensor - Sensor STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5501 has an error priority of Amber. Limp Home Implement Hydraulics operating mode is enabled with Diagnostic Trouble Code 5501. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Engine is On and Spool sensor voltage is less than 0.2 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Open wire in circuit.

3.

Boom Spool Position Sensor has failed.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5501 - Loader Arm Spool Sensor Sensor STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 9.

Check for open circuit. Disconnect connector X-22 from the BOOM SPOOL POSITION SENSOR. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check continuity between connector X-22 pin A and connector X-CN3B pin 13. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 571 (Yellow) between connector X-22 pin A and connector X-CN3B pin 13. Continue with step 3.

Locate the open circuit. Disconnect connector X-88 from X-10. Using a multi-meter, check continuity between connector X-10 pin 8 and connector X-CN3B pin 13. A.

If there is no continuity, there is an open wire condition on wire 571 (Yellow) between connector X-10 pin 8 and connector X-CN3B pin 13. Repair or replace the wire.

B.

If there is continuity, there is an open wire condition on wire 571 (Yellow) between connector X-88 pin 8 and connector X-22 pin A, or connectors X-88 and X-10 are not making a good connection at pin 8. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-22 pin A, or connector X-CN3B pin 13 and ground. A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 571 (Yellow) between connector X-22 pin A and connector X-CN3B pin 13. Continue with step 5.

Locate the short to ground. Disconnect connector X-88 from connector X-10. Using a multi-meter, check for continuity between connector X-10 pin 8, or connector X-CN3B pin 13 and ground. A.

If there is no continuity, there is a short to ground on wire 571 (Yellow) between connector X-22 pin A and X-88 pin 8. Repair or replace the shorted wire. 84522361 15/06/2011

A.50.A / 330

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

If there is continuity, there is a short to ground condition on wire 571 (Yellow) between connector X-10 pin 8 and connector X-CN3B pin 13. Repair or replace the shorted wire.

Check for proper resistance in the BOOM SPOOL POSITION SENSOR. Using a multi-meter to check for resistance between BOOM SPOOL POSITION SENSOR pins A and B. A.

If resistance is normal, continue with step 7.

B.

If resistance is infinite, the BOOM SPOOL POSITION SENSOR has developed an open. Replace the BOOM SPOOL POSITION SENSOR.

C.

If resistance is 0 Ω, the BOOM SPOOL POSITION SENSOR has shorted internally. Replace the BOOM SPOOL POSITION SENSOR.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-22 pin B and ground. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 25, 24, and 1 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-13 and CN1A-1. A.

If resistance is normal, continue with step 9.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 150 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24)

84522361 15/06/2011

A.50.A / 331

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5502- Loader Arm Spool Sensor - Sensor STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5502 has an error priority of Amber. Limp Home Implement Hydraulics operating mode is enabled with Diagnostic Trouble Code 5502. Cause: UCM has sensed higher than normal voltage on the Loader Arm Spool Sensor. (The fault is only activated when Ignition is On and Loader Arm Spool Sensor voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Loader Arm Spool Sensor.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5502 - Loader Arm Spool Sensor Sensor STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for short to high. Disconnect connector X-22 from the BOOM SPOOL POSITION SENSOR. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check for voltage between connector X-22 pin A, or connector X-CN3B pin 13 and ground. A.

If there is no voltage, continue with step 4.

B.

If voltage greater than 4.8 V, there is a short to high source on wire 571 (Yellow) between connector X-22 pin A and connector X-CN3B pin 13. Continue with step 3.

Locate the short to high. Disconnect connector X-88 from X-10. Using a multi-meter, check for voltage between connector X-22 pin A and ground. A.

If there is no voltage, there is a short to high source on wire 571 (Yellow) between connector X-10 pin 8 and connector X-CN3B pin 13. Repair or replace the wire.

B.

If voltage greater than 4.8 V, there is a short to high source on wire 571 (Yellow) between connector X-22 pin A and connector X-88 pin 8. Repair or replace the wire.

Check for proper operation of the BOOM SPOOL POSITION SENSOR. Reconnect connector X-22 to the BOOM SPOOL POSITION SENSOR. Disconnect connector X-10 from connector X-88. Using a multi-meter, check for voltage between connector X-88 pin 8 and ground. A.

If voltage is greater than 4.8 V, the BOOM SPOOL POSITION SENSOR has failed. Replace the BOOM SPOOL POSITION SENSOR.

B.

If voltage is less than 4.8 V, continue with step 5.

Check for proper operation of the UCM. Reconnect connector X-CN3B to the UCM. Using a multi-meter, check for voltage between connector X-10 pin 8 and ground. A.

If voltage is greater than 4.8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 4.8 V, continue with step 6. 84522361 15/06/2011

A.50.A / 332

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 333

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5504- Bucket Valve Spool sensor - Sensor STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5504 has an error priority of Amber. Limp Home Implement Hydraulics operating mode is enabled with Diagnostic Trouble Code 5504. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Ignition is On and Bucket Spool Position Sensor voltage is less than 0.2 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Open wire in circuit.

3.

Bucket Spool Position Sensor has failed.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5504 - Bucket Valve Spool sensor Sensor STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 10.

Check for open circuit. Disconnect connector X-21 from the BUCKET SPOOL POSITION SENSOR. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check continuity between connector X-21 pin 4 and connector X-CN3B pin 12. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 570 (Yellow) between connector X-21 pin 4 and connector X-CN3B pin 12. Continue with step 3.

Locate the open circuit. Disconnect connector X-88 from connector X-10. Using a multi-meter, check continuity between connector X-10 pin 4 and connector X-CN3B pin 12. A.

If there is no continuity, there is an open wire condition on wire 570 (Yellow) between connector X-10 pin 4 and connector X-CN3B pin 12. Repair or replace the wire.

B.

If there is continuity, Continue with step 4.

Locate the open circuit. Using a multi-meter, check continuity between connector X-88 pin 4 and connector X-21 pin 4. A.

If there is no continuity, there is an open wire condition on wire 570 (Yellow) between connector X-88 pin 4 and connector X-21 pin 4. Repair or replace the wire.

B.

If there is continuity, connectors X-88 and X-10 are not making a good connection at pin 4. Repair or replace the connector.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-21 pin 4, or connector X-CN3B pin 12 and ground. A.

If there is no continuity, continue with step 7.

84522361 15/06/2011

A.50.A / 334

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

10.

If there is continuity, there is a short to ground condition on wire 570 (Yellow) between connector X-21 pin 4 and connector X-CN3B pin 12. Continue with step 6.

Locate the short to ground. Disconnect connector X-88 from connector X-10. Using a multi-meter, check for continuity between connector X-10 pin 4, or connector X-CN3B pin 12 and ground. A.

If there is no continuity, there is a short to ground on wire 570 (Yellow) between connector X-21 pin 4 and X-88 pin 4. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 570 (Yellow) between connector X-10 pin 4 and connector X-CN3B pin 12. Repair or replace the shorted wire.

Check for proper resistance in the BUCKET SPOOL POSITION SENSOR. Using a multi-meter to check for resistance between BUCKET SPOOL POSITION SENSOR pins 3 and 4. A.

If resistance is normal, continue with step 8.

B.

If resistance is infinite, the BUCKET SPOOL POSITION SENSOR has developed an open. Replace the BUCKET SPOOL POSITION SENSOR.

C.

If resistance is 0 Ω, the BUCKET SPOOL POSITION SENSOR has shorted internally. Replace the BUCKET SPOOL POSITION SENSOR.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-21 pin 3 and ground. A.

If there is continuity, continue with step 9.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 23, 24, 25 and 1 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-12 and CN1A-1. A.

If resistance is normal, continue with step 10.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) harness - Electrical schematic frame 23 (A.30.A.88-C.20.E.23) harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01) harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 335

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5505- Bucket Valve Spool sensor - Sensor STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5505 has an error priority of Amber. Limp Home Implement Hydraulics operating mode is enabled with Diagnostic Trouble Code 5505. Cause: UCM has sensed higher than normal voltage on the Bucket Valve Spool Sensor. (The fault is only activated when Ignition is On and Bucket Valve Spool Sensor voltage is high.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Bucket Valve Spool Sensor.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5505 - Bucket Valve Spool sensor Sensor STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for short to high. Disconnect connector X-CN3B from the UCM. Disconnect connector X-21 from the BUCKET SPOOL POSITION SENSOR. Using a multi-meter, check for voltage between connector X-21 pin 4, or connector X-CN3B pin 12 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 570 (Yellow) between connector X-21 pin 4 and connector X-CN3B pin 12. Continue with step 3.

Locate the short to high. Disconnect connector X-88 from connector X-10. Using a multi-meter, check for voltage between connector X-21 pin 4 and ground. A.

If there is no voltage, there is a short to high source on wire 570 (Yellow) between connector X-10 pin 4 and connector X-CN3B pin 12. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 570 (Yellow) between connector X-21 pin 4 and connector X-88 pin 4. Repair or replace the wire.

Check for proper operation of the BUCKET SPOOL POSITION SENSOR. Reconnect connector X-21 to the BUCKET SPOOL POSITION SENSOR. Using a multi-meter, check for voltage between connector X-CN3B pin 12 and ground. A.

If voltage is greater than 4.8 V, the BUCKET SPOOL POSITION SENSOR has failed. Replace the BUCKET SPOOL POSITION SENSOR.

B.

If voltage is less than 4.8 V, continue with step 5.

Check for proper operation of the UCM. Reconnect connector X-CN3B to the UCM. Disconnect connector X-10 from connector X-88. Using a multi-meter, check for voltage between connector X-10 pin 4 and ground. A.

If voltage is greater than 4.8 V, the UCM has failed. Replace the UCM.

B.

If voltage is less than 4.8 V, continue with step 6. 84522361 15/06/2011

A.50.A / 336

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 337

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5507-Auxiliary Valve Spool Sensor - Sensor STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5507 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Aux operating mode is enabled with Diagnostic Trouble Code 5507. Cause: UCM has sensed that the 5 V signal has failed low. (The fault is only activated when Engine is on and spool sensor voltage is less than 0.2 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Open wire in circuit.

3.

Auxiliary Valve Spool Sensor has failed.

4.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5507 - Auxiliary Valve Spool Sensor - Sensor STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 9.

Check for open circuit. Disconnect connector X-23 from the AUXILIARY SPOOL POSITION SENSOR. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check continuity between connector X-23 pin 4 and connector X-CN3B pin 14. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 572 (Yellow) between connector X-23 pin 13 and connector X-CN3B pin 14. Continue with step 3.

Locate the open circuit. Disconnect connector X-88 from X-10. Using a multi-meter, check continuity between connector X-10 pin 13 and connector X-CN3B pin 14. A.

If there is no continuity, there is an open wire condition on wire 572 (Yellow) between connector X-10 pin 13 and connector X-CN3B pin 14. Repair or replace the wire.

B.

If there is continuity, there is an open wire condition on wire 572 (Yellow) between connector X-88 pin 13 and connector X-23 pin 4, or connectors X-88 and X-10 are not making a good connection at pin 13. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-23 pin 4, or connector X-CN3B pin 14 and ground. A.

If there is no continuity, continue with step 6.

B.

If there is continuity, there is a short to ground condition on wire 572 (Yellow) between connector X-23 pin 13 and connector X-CN3B pin 14. Continue with step 5.

Locate the short to ground. Disconnect connector X-88 from connector X-10. Using a multi-meter, check for continuity between connector X-10 pin 13, or connector X-CN3B pin 14 and ground. 84522361 15/06/2011

A.50.A / 338

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

9.

A.

If there is no continuity, there is a short to ground on wire 572 (Yellow) between connector X-23 pin 4 and X-88 pin 13. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 572 (Yellow) between connector X-10 pin 13 and connector X-CN3B pin 14. Repair or replace the shorted wire.

Check for proper resistance in the AUXILIARY SPOOL POSITION SENSOR. Using a multi-meter to check for resistance between AUXILIARY SPOOL POSITION SENSOR pins 3 and 4. A.

If resistance is normal, continue with step 7.

B.

If resistance is infinite, the AUXILIARY SPOOL POSITION SENSOR has developed an open. Replace the AUXILIARY SPOOL POSITION SENSOR.

C.

If resistance is 0 Ω, the AUXILIARY SPOOL POSITION SENSOR has shorted internally. Replace the AUXILIARY SPOOL POSITION SENSOR.

Check for proper resistance in the ground circuit by using a multi-meter to check for continuity between connector X-23 pin 3 and ground. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open in the ground circuit. Use Frames 26, 23, 24, 25 and 1 to troubleshoot and isolate the faulty wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-14 and CN1A-1. A.

If resistance is normal, continue with step 9.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 339

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5508- Auxiliary Valve Spool Sensor - Sensor STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5508 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Aux operating mode is enabled with Diagnostic Trouble Code 5508. Cause: UCM has sensed higher than normal voltage on the Auxiliary Valve Spool Sensor. (The fault is only activated when Ignition is On and Auxiliary Valve Spool Sensor voltage is greater than 4.8 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Auxiliary Valve Spool Sensor.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5508 - Auxiliary Valve Spool Sensor - Sensor STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for short to high. Disconnect connector X-CN3B from the UCM. Disconnect connector X-23 from the AUXILIARY SPOOL POSITION SENSOR. Using a multi-meter, check for voltage between connector X-23 pin 13, or connector X-CN3B pin 14 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 572 (Yellow) between connector X-23 pin 4 and connector X-CN3B pin 14. Continue with step 3.

Locate the short to high. Disconnect connector X-88 from X-10. Using a multi-meter, check for voltage between connector X-23 pin 4 and ground. A.

If there is no voltage, there is a short to high source on wire 572 (Yellow) between connector X-10 pin 13 and connector X-CN3B pin 14. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 572 (Yellow) between connector X-23 pin 4 and connector X-88 pin 13. Repair or replace the wire.

Check for proper operation of the AUXILIARY SPOOL POSITION SENSOR. Reconnect connector X-23 to the AUXILIARY SPOOL POSITION SENSOR. Disconnect connector X-10 from connector X-88. Using a multi-meter, check for voltage between connector X-88 pin 13 and ground. A.

If voltage is greater than 4.8 V, the AUXILIARY SPOOL POSITION SENSOR has failed. Replace the AUXILIARY SPOOL POSITION SENSOR.

B.

If voltage is less than 4.8 V, continue with step 5.

Check for proper operation of the UCM. Reconnect connector X-CN3B to the UCM. Using a multi-meter, check for voltage between connector X-10 pin 13 and ground. A.

If voltage is greater than 4.8 V, the UCM has failed. Replace the UCM. 84522361 15/06/2011

A.50.A / 340

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

If voltage is less than 4.8 V, continue with step 6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 341

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5511- Loader Arm Spool Sensor - implausible state sensor vs loader arm command, stuck spool/PRV L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5511 has an error priority of Red. Loader Hydraulics are disabled with Diagnostic Trouble Code 5511. Cause: UCM has sensed that the Boom Spool Position Sensor does not agree with the direction of Loader travel. (The fault is only activated when Engine is On and the Boom Spool Position Sensor senses Loader movement when the solenoids are not energized or Loader movement opposite of the energized solenoid.) Possible failure modes: 1.

Improper wiring in circuit.

2.

Failure of Boom Spool Position Sensor.

3.

Stuck open or shut valve boom spool.

Solution: 1.

2.

3.

4.

5.

Verify Boom Spool Valve is not mechanically stuck before troubleshooting this fault electrically. Use the machine to recreate conditions for error. Use the EST to verify 5511 - Loader Arm Spool Sensor - implausible state sensor vs loader arm command, stuck spool/PRV is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for proper connections to LOADER VALVE RETRACT SOLENOID and LOADER VALVE EXTEND SOLENOID. Ensure that connector X-27 is connected to the LOADER VALVE RETRACT SOLENOID. Ensure that connector X-28 is connected to the LOADER VALVE EXTEND SOLENOID. A.

If both connectors are correctly installed, continue with step 3.

B.

If either connector is not correctly installed, Use frame 24 to ensure connectors X-27 and X-28 are installed correctly.

Check for proper connections to AUXILIARY SPOOL POSITION SENSOR, BUCKET SPOOL POSITION SENSOR, and BOOM SPOOL POSITION SENSOR. Ensure that connector X-21 is connected to the BUCKET SPOOL POSITION SENSOR. Ensure that connector X-22 is connected to the BOOM SPOOL POSITION SENSOR. Ensure that connector X-23 is connected to the AUXILIARY SPOOL POSITION SENSOR. A.

If all connectors are correctly installed, continue with step 4.

B.

If any connector is not correctly installed, Use frame 24 to ensure connectors X-21, X-22, and X-23, are installed correctly.

Check Instrument Cluster or EST for other Trouble Codes. A.

If the other Trouble Codes are active, follow the procedure for those first.

B.

If the no other Trouble Codes are active, the BOOM SPOOL POSITION SENSOR has failed. Replace the BOOM SPOOL POSITION SENSOR.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent 84522361 15/06/2011

A.50.A / 342

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25)

84522361 15/06/2011

A.50.A / 343

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5512- Bucket Valve Spool sensor - implausible state sensor vs loader bucket command L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5512 has an error priority of Red. Loader Hydraulics are disabled with Diagnostic Trouble Code 5512. Cause: UCM has sensed that the Bucket Spool Position Sensor does not agree with the direction of Bucket travel. (The fault is only activated when Engine is On and the Bucket Spool Position Sensor senses Bucket movement when the solenoids are not energized or Bucket movement opposite of the energized solenoid.) Possible failure modes: 1.

Improper wiring in circuit.

2.

Failure of Bucket Spool Position Sensor.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5512 - Bucket Valve Spool sensor implausible state sensor vs loader bucket command is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for proper connections to BUCKET VALVE RETRACT SOLENOID and BUCKET VALVE EXTEND SOLENOID. Ensure that connector X-25 is connected to the BUCKET VALVE RETRACT SOLENOID. Ensure that connector X-26 is connected to the BUCKET VALVE EXTEND SOLENOID. A.

If both connectors are correctly installed, continue with step 3.

B.

If either connector is not correctly installed, Use frame 24 to ensure connectors X-25 and X-26 are installed correctly.

Check for proper connections to AUXILIARY SPOOL POSITION SENSOR, BUCKET SPOOL POSITION SENSOR, and BOOM SPOOL POSITION SENSOR. Ensure that connector X-21 is connected to the BUCKET SPOOL POSITION SENSOR. Ensure that connector X-22 is connected to the BOOM SPOOL POSITION SENSOR. Ensure that connector X-23 is connected to the AUXILIARY SPOOL POSITION SENSOR. A.

If all connectors are correctly installed, continue with step 4.

B.

If either connector is not correctly installed, Use frame 24 to ensure connectors X-21, X-22, and X-23, are installed correctly.

Check Instrument Cluster for other Trouble Codes. A.

If the other Trouble Codes are active, follow the procedure for those first.

B.

If the no other Trouble Codes are active, the BUCKET SPOOL POSITION SENSOR has failed. Replace the BUCKET SPOOL POSITION SENSOR.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. 84522361 15/06/2011

A.50.A / 344

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25)

84522361 15/06/2011

A.50.A / 345

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5513- Auxiliary Valve Spool Sensor - implausible state sensor vs auxiliary command L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5513 has an error priority of Hydraulic-Amber. Loader Hydraulics are is disabled with Diagnostic Trouble Code 5513. Cause: UCM has sensed that the Auxiliary Valve Spool Position Sensor does not agree with the direction of Auxiliary travel. (The fault is only activated when Engine is On and the Auxiliary Spool Position Sensor senses Auxiliary movement when the solenoids are not energized or Auxiliary movement opposite of the energized solenoid.) Possible failure modes: 1.

Improper wiring in circuit.

2.

Failure of Auxiliary Spool Position Sensor.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5513 - Auxiliary Valve Spool Sensor - implausible state sensor vs auxiliary command is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for proper connections to PROPORTIONAL AUX VALVE RETRACT SOLENOID and PROPORTIONAL AUX VALVE EXTEND SOLENOID. Ensure that connector X-29 is connected to the PROPORTIONAL AUX VALVE RETRACT SOLENOID. Ensure that connector X-24 is connected to the PROPORTIONAL AUX VALVE EXTEND SOLENOID. A.

If both connectors are correctly installed, continue with step 3.

B.

If either connector is not correctly installed, Use frame 24 to ensure connectors X-29 and X-24 are installed correctly.

Check for proper connections to AUXILIARY SPOOL POSITION SENSOR, BUCKET SPOOL POSITION SENSOR, and BOOM SPOOL POSITION SENSOR. Ensure that connector X-21 is connected to the BUCKET SPOOL POSITION SENSOR. Ensure that connector X-22 is connected to the BOOM SPOOL POSITION SENSOR. Ensure that connector X-23 is connected to the AUXILIARY SPOOL POSITION SENSOR. A.

If all connectors are correctly installed, continue with step 4.

B.

If either connector is not correctly installed, Use frame 24 to ensure connectors X-21, X-22, and X-23 are installed correctly.

Check Instrument Cluster for other Trouble Codes. A.

If the other Trouble Codes are active, follow the procedure for those first.

B.

If the no other Trouble Codes are active, the AUXILIARY SPOOL POSITION SENSOR has failed. Replace the AUXILIARY SPOOL POSITION SENSOR.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. 84522361 15/06/2011

A.50.A / 346

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25)

84522361 15/06/2011

A.50.A / 347

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5601- Aux Valve (Directional) - Common Solenoid Return STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Fault code 5601 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Aux is enabled with Fault code 5601. Cause: UCM has sensed higher than normal voltage on the Proportional Aux Valve Solenoid Common Return. (The fault is only activated when Ignition is on, hydraulics are disabled, and solenoid voltage feedback is greater than 5 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5601 - Aux Valve (Directional) - Common Solenoid Return STP is present. A.

If the fault is present, continue with step 2.

B.

If the fault is not present, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high. Disconnect connector X-CN1B from the UCM. Disconnect connector X-CN1A from the UCM. Disconnect connector X-29 from the PROPORTIONAL AUX VALVE RETRACT. Disconnect connector X-24 from the PROPORTIONAL AUX VALVE EXTEND. Using a multi-meter, check for voltage between connector X-29 pin 1 and ground. A.

If there is no voltage, continue with step 3.

B.

If there is voltage, there is a short to high source on wire 515 (White) between connector X-29 pin 1 and connector X-CN1A pin 24. Repair or replace the wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-24 pin 1 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 514 (White) between connector X-CN1B pin 33 and connector X-24 pin 1. Repair or replace the wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-29 pin 2 and ground. A.

If there is no voltage, continue with step 5.

B.

If there is voltage, there is a short to high source on wire 1020/1082 (Blue) between connector X-CN1A pin 22 and connector X-29 pin 2, or on wire 1083 (Blue) between SPLICE 156 and connector X-24 pin 2. Repair or replace the wire.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring.

84522361 15/06/2011

A.50.A / 348

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 349

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5602- Loader Auxiliary Valve (Directional) - Loader Auxiliary Solenoids STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5602 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable aux operating mode is enabled with Diagnostic Trouble Code 5602. Cause: UCM has sensed that the solenoid return voltage is low. (The fault is only activated when Hydraulics are disabled and solenoid return voltage feedback is low.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of UCM.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 5602 - Loader Auxiliary Valve (Directional) - Loader Auxiliary Solenoids STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for a short to ground. Disconnect connector X-24 from the PROPORTIONAL AUX VALVE EXTEND. Disconnect connector X-29 from the PROPORTIONAL AUX VALVE RETRACT. Disconnect connector X-CN1A from the UCM. Using a multi-meter, check for continuity between connector X-29 pin 2 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground condition on wire 1020/1082 (Blue) between connector X-CN1A pin 22 and connector X-29 pin 2, or on wire 1083 (Blue) between SPLICE 156 and connector X-24 pin 2. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1A-22 and CN1A-1. A.

If resistance is normal, continue with step 4.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 84522361 15/06/2011

A.50.A / 350

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 351

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5603- Loader Auxiliary Valve (Directional) - Solenoids Return OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5603 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Disable Aux operating mode is enabled with Diagnostic Trouble Code 5603. Cause: UCM has sensed improper Loader Auxiliary Valve solenoid current. (The fault is only activated when Hydraulics are enabled and solenoid supply current is incorrect.) Possible failure modes: 1.

Open wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5603 - Loader Auxiliary Valve (Directional) - Solenoids Return OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for an open wire condition. Disconnect connector X-CN1A from the UCM. Disconnect connector X-29 from the PROPORTIONAL AUX VALVE RETRACT SOLENOID. Disconnect connector X-24 from the PROPORTIONAL AUX VALVE EXTEND SOLENOID. Using a multi-meter, check for continuity between connector X-CN1A pin 22 and connector X-29 pin 2. A.

If there is no continuity, there is an open wire condition on wire 1020 (Blue) between connector X-CN1A pin 22 and SPLICE 156. Continue with step 3.

B.

If there is continuity, continue with step 5.

Check for an open wire condition. Disconnect connector X-88 from connector X-10. Using a multi-meter, check for continuity between connector X-88 pin 11 and connector X-29 pin 2. A.

If there is no continuity, there is an open wire condition on wire 1020 (Blue) between connector X-88 pin 11 and SPLICE 156. Repair or replace wire.

B.

If there is continuity, continue with step 4.

Check for an open wire condition. Using a multi-meter, check for continuity between connector X-10 pin 11 and connector X-CN1A pin 22. A.

If there is no continuity, there is an open wire condition on wire 1020 (Blue) between connector X-10 pin 11 and connector X-CN1A pin 22. Repair or replace wire.

B.

If there is continuity, connectors X-10 and X-88 are not making a good connection at pin 11. Repair the connector.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1A-22 and CN1A-1. A.

If resistance is normal, continue with step 6.

B.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM. 84522361 15/06/2011

A.50.A / 352

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 24 (A.30.A.88-C.20.E.24) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26)

84522361 15/06/2011

A.50.A / 353

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5701- Pattern Switch - STG / OC L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5701 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Freeze Current Pattern is enabled with Diagnostic Trouble Code 5701. Cause: UCM has sensed all 3 Drive Pattern Select pins are low. (The fault is only activated when Engine is on and all 3 pins are less than 1.5 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Open wire in circuit.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5701 - Pattern Switch - STG / OC is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 11.

Check for short to ground. Disconnect connector X-CN2B from the UCM. Disconnect connector X-CN1B from the UCM. Disconnect connector X-95 from the DRIVE PATTERN SELECT. Using a multi-meter, check for continuity between connector X-95 pin 3 and ground. A.

If there is no continuity, continue with step 3.

B.

If there is continuity, there is a short to ground on wire 521 (Yellow) between connector X-95 pin 3 and connector X-CN1B pin 15. Repair or replace the wire.

Check for short to ground. Using a multi-meter, check for continuity between connector X-95 pin 1 and ground. A.

If there is no continuity, continue with step 4.

B.

If there is continuity, there is a short to ground on wire 522 (Yellow) between connector X-95 pin 1 and connector X-CN2B pin 20. Repair or replace the wire.

Check for short to ground. Using a multi-meter, check for continuity between connector X-95 pin 6 and ground. A.

If there is no continuity, continue with step 5.

B.

If there is continuity, there is a short to ground on wire 523 (Yellow) between connector X-95 pin 6 and connector X-CN2B pin 21. Repair or replace the wire.

Check for an open circuit. Using a multi-meter, check for continuity between connector X-95 pin 1 and connector X-CN2B pin 20. A.

If there is continuity, continue with step 6.

B.

If there is no continuity, there is an open on wire 522 (Yellow) between connector X-95 pin 1 and connector X-CN2B pin 20, or connectors X-ECC4B and X-ECC4A are not making a good connection at pin 9. Repair or replace the wire. 84522361 15/06/2011

A.50.A / 354

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

9.

10.

11.

Check for an open circuit. Using a multi-meter, check for continuity between connector X-95 pin 3 and connector X-CN1B pin 15. A.

If there is continuity, continue with step 7.

B.

If there is no continuity, there is an open on wire 521 (Yellow) between connector X-95 pin 3 and connector X-CN1B pin 15, or connectors X-ECC4B and X-ECC4A are not making a good connection at pin 4. Repair or replace the wire.

Check for an open circuit. Using a multi-meter, check for continuity between connector X-95 pin 6 and connector X-CN2B pin 21. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open on wire 523 (Yellow) between connector X-95 pin 6 and connector X-CN2B pin 21, or connectors X-ECC4B and X-ECC4A are not making a good connection at pin 11. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-15 and CN1A-1. A.

If resistance is normal, continue with step 9.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2B-20 and CN1A-1. A.

If resistance is normal, continue with step 10.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2B-21 and CN1A-1. A.

If resistance is normal, continue with step 11.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 06 (A.30.A.88-C.20.E.06)

84522361 15/06/2011

A.50.A / 355

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5703- Pattern Switch - STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5703 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Freeze Current Pattern is enabled with Diagnostic Trouble Code 5703. Cause: UCM has sensed 2 or more Drive Pattern Select pins are high. (The fault is only activated when Ignition is on and 2 or more pins are greater than 3.5 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5703 - Pattern Switch - STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 5.

Check for short to high. Disconnect connector X-CN2B from the UCM. Disconnect connector X-CN1B from the UCM. Disconnect connector X-95 from the DRIVE PATTERN SELECT. Using a multi-meter, check for voltage between connector X-95 pin 3 and ground. A.

If there is no voltage, continue with step 3.

B.

If there is voltage, there is a short to high source on wire 521 (Yellow) between connector X-95 pin 3 and connector X-CN1B pin 15. Repair or replace the wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-95 pin 1 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 522 (Yellow) between connector X-95 pin 1 and connector X-CN2B pin 20. Repair or replace the wire.

Check for short to high. Using a multi-meter, check for voltage between connector X-95 pin 6 and ground. A.

If there is no voltage, continue with step 5.

B.

If there is voltage, there is a short to high source on wire 523 (Yellow) between connector X-95 pin 6 and connector X-CN2B pin 21. Repair or replace the wire.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved. 84522361 15/06/2011

A.50.A / 356

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 06 (A.30.A.88-C.20.E.06)

84522361 15/06/2011

A.50.A / 357

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

5811- switch - implausible state L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 5811 has an error priority of Amber. There are no restrictions with Diagnostic Trouble Code 5811. Cause: UCM has sensed an implausible state of the Loader Lockout switch. (The fault is activated when Engine is on, EU Roading Option is activated, and both inputs are greater than 3.5 V or both inputs are less than 1.5 V.) Possible failure modes: 1.

Open or shorted wire in circuit.

2.

Failure of Loader Lockout switch.

3.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 5811 - switch - implausible state is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 18.

Check for open circuit. Disconnect connector X-306 from the LOADER LOCKOUT SWITCH. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check continuity between connector X-306 pin C and connector X-CN2B pin 23. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 398 (Yellow) between connector X-306 pin C and connector X-CN2B pin 23. Continue with step 3.

Locate the open circuit. Disconnect connector X-ECC4B from connector X-ECC4A. Using a multi-meter, check continuity between connector X-ECC4B pin 3 and connector X-CN2B pin 23. A.

If there is no continuity, there is an open wire condition on wire 398 (Yellow) between connector X-ECC4B pin 3 and connector X-CN2B pin 23. Repair or replace the wire.

B.

If there is continuity, continue with step 4.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC4A pin 3 and connector X-306 pin C. A.

If there is no continuity, there is an open wire condition on wire 398 (Yellow) between connector X-ECC4A pin 3 and connector X-306 pin C. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC4B and X-ECC4A are not making a good connection at pin 3. Repair the connector.

Check for open circuit. Disconnect connector X-306 from the LOADER LOCKOUT SWITCH. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check continuity between connector X-306 pin A and connector X-CN3B pin 19. A.

If there is continuity, continue with step 8.

84522361 15/06/2011

A.50.A / 358

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

7.

8.

9.

10.

11.

12.

13.

If there is no continuity, there is an open wire condition on wire 312 (Yellow) between connector X-306 pin A and connector X-CN3B pin 19. Continue with step 6.

Locate the open circuit. Disconnect connector X-ECC4B from connector X-ECC4A. Using a multi-meter, check continuity between connector X-ECC4B pin 12 and connector X-CN3B pin 19. A.

If there is no continuity, there is an open wire condition on wire 312 (Yellow) between connector X-ECC4B pin 12 and connector X-CN3B pin 19. Repair or replace the wire.

B.

If there is continuity, continue with step 7.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC4A pin 12 and connector X-306 pin A. A.

If there is no continuity, there is an open wire condition on wire 312 (Yellow) between connector X-ECC4A pin 12 and connector X-306 pin A. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC4B and X-ECC4A are not making a good connection at pin 12. Repair the connector.

Check for a short to ground. Disconnect connector X-306 from the LOADER LOCKOUT SWITCH. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check for continuity between connector X-306 pin C, or connector X-CN2B pin 23 and ground. A.

If there is no continuity, continue with step 10.

B.

If there is continuity, there is a short to ground condition on wire 398 (Yellow) between connector X-306 pin C and connector X-CN2B pin 23. Continue with step 9.

Locate the short to ground. Disconnect connector X-ECC4B from connector X-ECC4A. Using a multi-meter, check for continuity between connector X-ECC4B pin 3, or connector X-CN2B pin 23 and ground. A.

If there is no continuity, there is a short to ground on wire 398 (Yellow) between connector X-306 pin C and X-ECC4A pin 3. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 398 (Yellow) between connector X-ECC4B pin 3 and connector X-CN2B pin 23. Repair or replace the shorted wire.

Check for a short to ground. Disconnect connector X-306 from the LOADER LOCKOUT SWITCH. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check for continuity between connector X-306 pin A, or connector X-CN3B pin 19 and ground. A.

If there is no continuity, continue with step 12.

B.

If there is continuity, there is a short to ground condition on wire 312 (Yellow) between connector X-306 pin A and connector X-CN3B pin 19. Continue with step 11.

Locate the short to ground. Disconnect connector X-ECC4B from connector X-ECC4A. Using a multi-meter, check for continuity between connector X-ECC4B pin 12, or connector X-CN3B pin 19 and ground. A.

If there is no continuity, there is a short to ground on wire 312 (Yellow) between connector X-306 pin A and X-ECC4A pin 12. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 312 (Yellow) between connector X-ECC4B pin 12 and connector X-CN3B pin 19. Repair or replace the shorted wire.

Check for short to high. Disconnect connector X-306 from the LOADER LOCKOUT SWITCH. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check for voltage between connector X-306 pin C, or connector X-CN2B pin 23 and ground. A.

If there is no voltage, continue with step 14.

B.

If there is voltage, there is a short to high source on wire 398 (Yellow) between connector X-306 pin C and connector X-CN2B pin 23. Continue with step 13.

Locate the short to high. Disconnect connector X-ECC4B from connector X-ECC4A. Using a multi-meter, check for voltage between connector X-306 pin C, or connector X-ECC4A pin 3 and ground.

84522361 15/06/2011

A.50.A / 359

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

14.

15.

16.

17.

18.

A.

If there is no voltage, there is a short to high source on wire 398 (Yellow) between connector X-ECC4B pin 3 and connector X-CN2B pin 23. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 398 (Yellow) between connector X-306 pin C and connector X-ECC4A pin 3. Repair or replace the wire.

Check for short to high. Disconnect connector X-306 from the LOADER LOCKOUT SWITCH. Disconnect connector X-CN3B from the UCM. Using a multi-meter, check for voltage between connector X-306 pin A, or connector X-CN3B pin 19 and ground. A.

If there is no voltage, continue with step 16.

B.

If there is voltage, there is a short to high source on wire 312 (Yellow) between connector X-306 pin A and connector X-CN3B pin 19. Continue with step 15.

Locate the short to high. Disconnect connector X-ECC4B from connector X-ECC4A. Using a multi-meter, check for voltage between connector X-306 pin A, or connector X-ECC4A pin 12 and ground. A.

If there is no voltage, there is a short to high source on wire 312 (Yellow) between connector X-ECC4B pin 12 and connector X-CN3B pin 19. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 312 (Yellow) between connector X-306 pin A and connector X-ECC4A pin 12. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2B-23 and CN1A-1. A.

If resistance is normal, continue with step 17.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN3B-19 and CN1A-1. A.

If resistance is normal, continue with step 18.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 25 (A.30.A.88-C.20.E.25) Wiring harness - Electrical schematic frame 06 (A.30.A.88-C.20.E.06)

84522361 15/06/2011

A.50.A / 360

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9151- CAN Connection - CAN communication timed out after 5 seconds L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 9151 has an error priority of Amber. Limp Home Loader Hydraulics operating mode and Limp Home Ground Drive operating mode are enabled with Diagnostic Trouble Code 9151. Cause: UCM has sensed that CAN messages are not received. (The fault is only activated when Ignition is On, code 1350 is not active, Crank Pin is low and CAN message is not received for 5 s.) Possible failure modes: 1.

Failure of Instrument Cluster.

2.

Failure of UCM.

3.

Open or shorted wire in system.

Solution: 1.

2.

3.

4.

5.

Trouble code 9151 may not be displayed on the Instrument Cluster due to the nature of the fault. Use indications of no trouble codes displayed on the Instrument Cluster with Limp Home Loader Hydraulics and Limp Home Ground Drive operating modes enabled to help determine if trouble code 9151 is active. Use the machine to recreate conditions for error. Use the EST to verify 9151 - CAN Connection - CAN communication timed out after 5 seconds is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 16.

Check for open circuit. Disconnect connector X-CN1B from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-CN1B pin 34 and connector X-C23 pin 4. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 500/503/502 (Yellow) between connector X-CN1B pin 34 and connector X-C23 pin 4. Continue with step 4.

Check for open circuit. Using a multi-meter, check continuity between connector X-CN1B pin 25 and connector X-C23 pin 6. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open wire condition on wire 505/504/507 (Green) between connector X-CN1B pin 25 and connector X-C23 pin 6. Continue with step 6.

Locate the open circuit. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check continuity between connector X-ECC1A pin 3 and connector X-C23 pin 4. A.

If there is no continuity, there is an open wire condition on wire 500/503 (Yellow) between connector X-ECC1A pin 3 and connector X-C23 pin 14. Repair or replace the wire.

B.

If there is continuity, continue with step 5.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC1B pin 3 and connector X-CN1B pin 34. 84522361 15/06/2011

A.50.A / 361

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

9.

10.

11.

12.

A.

If there is no continuity, there is an open wire condition on wire 502 (Yellow) between connector X-ECC1B pin 3 and connector X-CN1B pin 34. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC1A and X-ECC1B are not making a good connection at pin 3. Repair the connector.

Locate the open circuit. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check continuity between connector X-ECC1A pin 4 and connector X-C23 pin 6. A.

If there is no continuity, there is an open wire condition on wire 505/504 (Green) between connector X-ECC1A pin 4 and connector X-C23 pin 6. Repair or replace the wire.

B.

If there is continuity, continue with step 7.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC1B pin 4 and connector X-CN1B pin 25. A.

If there is no continuity, there is an open wire condition on wire 507 (Green) between connector X-ECC1B pin 4 and connector X-CN1B pin 25. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC1A and X-ECC1B are not making a good connection at pin 4. Repair the connector.

Check for a short to ground. Disconnect connector X-TELE from TELEMATICS. Using a multi-meter, check for continuity between connector X-CN1B pin 34, or connector X-C23 pin 4 and ground. A.

If there is no continuity, continue with step 9.

B.

If there is continuity, there is a short to ground condition on wire 500/503/502 (Yellow) between connector X-CN1B pin 25 and connector X-C23 pin 6. Continue with step 10.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-CN1B pin 25, or connector X-C23 pin 6 and ground. A.

If there is no continuity, continue with step 12.

B.

If there is continuity, there is a short to ground condition on wire 505/504/507 (Green) between connector X-CN1B pin 25 and connector X-C23 pin 6. Continue with step 11.

Locate the short to ground. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check for continuity between connector X-ECC1A pin 3, or connector X-C23 pin 4 and ground. A.

If there is no continuity, there is a short to ground on wire 502 (Yellow) between connector X-CN1B pin 34 and X-ECC1B pin 3 or between SPLICE 188 and connector X-TELE pin M. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 500/503 (Yellow) between connector X-ECC1A pin 3 and connector X-C23 pin 4. Repair or replace the shorted wire.

Locate the short to ground. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check for continuity between connector X-ECC1A pin 4, or connector X-C23 pin 6 and ground. A.

If there is no continuity, there is a short to ground on wire 507 (Green) between connector X-CN1B pin 25 and X-ECC1B pin 4 or between SPLICE 189 and connector X-TELE pin N. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 505/504 (Green) between connector X-ECC1A pin 3 and connector X-C23 pin 6. Repair or replace the shorted wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-34 and CN1A-1. A.

If resistance is normal, continue with step 13.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM. 84522361 15/06/2011

A.50.A / 362

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

13.

14.

15.

16.

Check for proper resistance of the UCM. Using a multi-meter, check for resistance between UCM pins CN1B-25 and CN1A-1. A.

If resistance is normal, continue with step 14.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 4 and 20. A.

If resistance is about 1.19 M Ω, continue with step 15.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 1.5 M Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 6 and 20. A.

If resistance is about 1.19 M Ω, continue with step 16.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 1.5 M Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM or Instrument Cluster as a failure point. Therefore, all other possibilities should be investigated before the UCM or Instrument Cluster is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 31 (A.30.A.88-C.20.E.31) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 30 (A.30.A.88-C.20.E.30)

84522361 15/06/2011

A.50.A / 363

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9152-CAN connection - CAN communication timed out after 5 seconds L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 9152 has an error priority of Red. All hydraulics are disabled with Diagnostic Trouble Code 9152. Cause: UCM has sensed that CAN messages are not received. (The fault is only activated when Ignition is On, code 1350 is active, Crank Pin is low and CAN message is not received for 5 s.) Possible failure modes: 1.

Failure of Instrument Cluster.

2.

Failure of UCM.

3.

Open or shorted wire in system.

Solution: 1.

2.

3.

4.

5.

Trouble code 9152 may not be displayed on the Instrument Cluster due to the nature of the fault. Use indications of no trouble codes displayed on the Instrument Cluster with no hydraulics available to help determine if trouble code 9152 is active. Use the machine to recreate conditions for error. Use the EST to verify 9152 - CAN connection - CAN communication timed out after 5 seconds is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 16.

Check for open circuit. Disconnect connector X-CN1B from the UCM. Disconnect connector X-C23 from the INSTRUMENT CLUSTER. Using a multi-meter, check continuity between connector X-CN1B pin 34 and connector X-C23 pin 4. A.

If there is continuity, continue with step 3.

B.

If there is no continuity, there is an open wire condition on wire 500/503/502 (Yellow) between connector X-CN1B pin 34 and connector X-C23 pin 4. Continue with step 4.

Check for open circuit. Using a multi-meter, check continuity between connector X-CN1B pin 25 and connector X-C23 pin 6. A.

If there is continuity, continue with step 8.

B.

If there is no continuity, there is an open wire condition on wire 505/504/507 (Green) between connector X-CN1B pin 25 and connector X-C23 pin 6. Continue with step 6.

Locate the open circuit. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check continuity between connector X-ECC1A pin 3 and connector X-C23 pin 4. A.

If there is no continuity, there is an open wire condition on wire 500/503 (Yellow) between connector X-ECC1A pin 3 and connector X-C23 pin 14. Repair or replace the wire.

B.

If there is continuity, continue with step 5.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC1B pin 3 and connector X-CN1B pin 34.

84522361 15/06/2011

A.50.A / 364

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

7.

8.

9.

10.

11.

12.

A.

If there is no continuity, there is an open wire condition on wire 502 (Yellow) between connector X-ECC1B pin 3 and connector X-CN1B pin 34. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC1A and X-ECC1B are not making a good connection at pin 3. Repair the connector.

Locate the open circuit. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check continuity between connector X-ECC1A pin 4 and connector X-C23 pin 6. A.

If there is no continuity, there is an open wire condition on wire 505/504 (Green) between connector X-ECC1A pin 4 and connector X-C23 pin 6. Repair or replace the wire.

B.

If there is continuity, continue with step 7.

Locate the open circuit. Using a multi-meter, check continuity between connector X-ECC1B pin 4 and connector X-CN1B pin 25. A.

If there is no continuity, there is an open wire condition on wire 507 (Green) between connector X-ECC1B pin 4 and connector X-CN1B pin 25. Repair or replace the wire.

B.

If there is continuity, connectors X-ECC1A and X-ECC1B are not making a good connection at pin 4. Repair the connector.

Check for a short to ground. Disconnect connector X-TELE from TELEMATICS. Using a multi-meter, check for continuity between connector X-CN1B pin 34, or connector X-C23 pin 4 and ground. A.

If there is no continuity, continue with step 9.

B.

If there is continuity, there is a short to ground condition on wire 500/503/502 (Yellow) between connector X-CN1B pin 25 and connector X-C23 pin 6. Continue with step 10.

Check for a short to ground. Using a multi-meter, check for continuity between connector X-CN1B pin 25, or connector X-C23 pin 6 and ground. A.

If there is no continuity, continue with step 12.

B.

If there is continuity, there is a short to ground condition on wire 505/504/507 (Green) between connector X-CN1B pin 25 and connector X-C23 pin 6. Continue with step 11.

Locate the short to ground. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check for continuity between connector X-ECC1A pin 3, or connector X-C23 pin 4 and ground. A.

If there is no continuity, there is a short to ground on wire 502 (Yellow) between connector X-CN1B pin 34 and X-ECC1B pin 3 or between SPLICE 188 and connector X-TELE pin M. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 500/503 (Yellow) between connector X-ECC1A pin 3 and connector X-C23 pin 4. Repair or replace the shorted wire.

Locate the short to ground. Disconnect connector X-ECC1A from connector X-ECC1B. Using a multi-meter, check for continuity between connector X-ECC1A pin 4, or connector X-C23 pin 6 and ground. A.

If there is no continuity, there is a short to ground on wire 507 (Green) between connector X-CN1B pin 25 and X-ECC1B pin 4 or between SPLICE 189 and connector X-TELE pin N. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 505/504 (Green) between connector X-ECC1A pin 3 and connector X-C23 pin 6. Repair or replace the shorted wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1B-34 and CN1A-1. A.

If resistance is normal, continue with step 13.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM. 84522361 15/06/2011

A.50.A / 365

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

13.

14.

15.

16.

Check for proper resistance of the UCM. Using a multi-meter, check for resistance between UCM pins CN1B-25 and CN1A-1. A.

If resistance is normal, continue with step 14.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 4 and 20. A.

If resistance is about 1.19 M Ω, continue with step 15.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 1.5 M Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Check for proper resistance of the INSTRUMENT CLUSTER. Using a multi-meter, check for resistance between INSTRUMENT CLUSTER pins 6 and 20. A.

If resistance is about 1.19 M Ω, continue with step 16.

B.

If resistance is 0 Ω, the INSTRUMENT CLUSTER has shorted internally. Replace the INSTRUMENT CLUSTER.

C.

If resistance is greater than 1.5 M Ω, the INSTRUMENT CLUSTER has opened internally. Replace the INSTRUMENT CLUSTER.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B. Wiring Wiring Wiring Wiring Wiring

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03) harness - Electrical schematic frame 31 (A.30.A.88-C.20.E.31) harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) harness - Electrical schematic frame 30 (A.30.A.88-C.20.E.30)

84522361 15/06/2011

A.50.A / 366

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9158- H pattern indicator - STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 9158 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Flash Pattern to Text display occurs with Diagnostic Trouble Code 9158. Cause: UCM has sensed that the H-Pattern indicator voltage signal has failed. (The fault is only activated when ISO Pattern is active and Pattern Select voltage is less than 5 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 9158 - H pattern indicator - STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for a short to ground. Disconnect connector X-95 from the DRIVE PATTERN SELECTOR. Disconnect connector X-CN2A from the UCM. Using a multi-meter, check for continuity between connector X-95 pin 8, or connector X-CN2A pin 23 and ground. A.

If there is no continuity, continue with step 4.

B.

If there is continuity, there is a short to ground condition on wire 1024 (Blue) between connector X-95 pin 8 and connector X-CN2A pin 23. Continue with step 3.

Locate the short to ground. Disconnect connector X-ECC3B from connector X-ECC3A. Using a multi-meter, check for continuity between connector X-ECC3B pin 8, or connector X-CN2A pin 23 and ground. A.

If there is no continuity, there is a short to ground on wire 1024 (Blue) between connector X-95 pin 8 and X-ECC3A pin 8. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 1024 (Blue) between connector X-ECC3B pin 8 and connector X-CN2A pin 23. Repair or replace the shorted wire.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) Wiring harness - Electrical schematic frame 06 (A.30.A.88-C.20.E.06) 84522361 15/06/2011

A.50.A / 367

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9159- ISO pattern indicator - STG L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 9159 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Flash Pattern to Text display occurs with Diagnostic Trouble Code 9159. Cause: UCM has sensed that the ISO-Pattern indicator voltage signal has failed. (The fault is only activated when H-Pattern is active and Pattern Select voltage is less than 5 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

UCM has internal failure.

Solution: 1.

2.

3.

4.

Use the machine to recreate conditions for error. Use the EST to verify 9159 - ISO pattern indicator - STG is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 4.

Check for a short to ground. Disconnect connector X-95 from the DRIVE PATTERN SELECTOR. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check for continuity between connector X-95 pin 9, or connector X-CN2B pin 2 and ground. A.

If there is no continuity, continue with step 4.

B.

If there is continuity, there is a short to ground condition on wire 1023 (Blue) between connector X-95 pin 9 and connector X-CN2B pin 2. Continue with step 3.

Locate the short to ground. Disconnect connector X-ECC3B from connector X-ECC3A. Using a multi-meter, check for continuity between connector X-ECC3B pin 6, or connector X-CN2B pin 2 and ground. A.

If there is no continuity, there is a short to ground on wire 1023 (Blue) between connector X-95 pin 9 and X-ECC3A pin 6. Repair or replace the shorted wire.

B.

If there is continuity, there is a short to ground condition on wire 1023 (Blue) between connector X-ECC3B pin 6 and connector X-CN2B pin 2. Repair or replace the shorted wire.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) Wiring harness - Electrical schematic frame 06 (A.30.A.88-C.20.E.06) 84522361 15/06/2011

A.50.A / 368

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9160- H pattern indicator - STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 9160 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Flash Pattern to Text display occurs with Diagnostic Trouble Code 9160. Cause: UCM has sensed that the H-Pattern indicator voltage signal has failed. (The fault is only activated when H-Pattern is active and Drive Pattern Selector voltage is greater than 8 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Drive Pattern Selector.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 9160 - H pattern indicator - STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for short to high. Disconnect connector X-95 from the DRIVE PATTERN SELECTOR. Disconnect connector X-CN2A from the UCM. Using a multi-meter, check for voltage between connector X-95 pin 8, or connector X-CN2A pin 23 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 1024 (Blue) between connector X-95 pin 8 and connector X-CN2A pin 23. Continue with step 3.

Locate the short to high. Disconnect connector X-ECC3B from connector X-ECC3A. Using a multi-meter, check for voltage between connector X-95 pin 8, or connector X-ECC3A pin 8 and ground. A.

If there is no voltage, there is a short to high source on wire 1024 (Blue) between connector X-ECC3B pin 8 and connector X-CN2A pin 23. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 1024 (Blue) between connector X-95 pin 8 and connector X-ECC3A pin 8. Repair or replace the wire.

Check for proper operation of the DRIVE PATTERN SELECTOR. Reconnect connector X-95 to the DRIVE PATTERN SELECTOR. Disconnect connector X-ECC3A from connector X-ECC3B. Using a multi-meter, check for voltage between connector X-ECC3A pin 8 and ground. A.

If voltage is greater than 8 V, the DRIVE PATTERN SELECTOR has failed. Replace the DRIVE PATTERN SELECTOR.

B.

If voltage is less than 8 V, continue with step 5.

Check for proper operation of the UCM. Reconnect connector X-CN2A to the UCM. Using a multi-meter, check for voltage between connector X-ECC3B pin 8 and ground. A.

If voltage is greater than 8 V, the UCM has failed. Replace the UCM. 84522361 15/06/2011

A.50.A / 369

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

If voltage is less than 8 V, continue with step 6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) Wiring harness - Electrical schematic frame 06 (A.30.A.88-C.20.E.06)

84522361 15/06/2011

A.50.A / 370

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

9161- ISO pattern indicator - STP L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCM Context: Diagnostic Trouble Code 9161 has an error priority of White. White errors are not displayed on the Instrument Cluster and are not known to the Owner/Operator. They will appear in the EST fault stack when the technician checks for active trouble codes while troubleshooting another fault. Flash Pattern to Text display occurs with Diagnostic Trouble Code 9161. Cause: UCM has sensed that the ISO Pattern indicator voltage signal has failed. (The fault is only activated when ISO Pattern is active and Drive Pattern Selector voltage is greater than 8 V.) Possible failure modes: 1.

Shorted wire in circuit.

2.

Failure of Drive Pattern Selector.

3.

UCM has internal failure.

Solution: 1.

2.

3.

4.

5.

Use the machine to recreate conditions for error. Use the EST to verify 9161 - ISO pattern indicator - STP is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for short to high. Disconnect connector X-95 from the DRIVE PATTERN SELECTOR. Disconnect connector X-CN2B from the UCM. Using a multi-meter, check for voltage between connector X-95 pin 9, or connector X-CN2B pin 2 and ground. A.

If there is no voltage, continue with step 4.

B.

If there is voltage, there is a short to high source on wire 1023 (Blue) between connector X-95 pin 9 and connector X-CN2B pin 2. Continue with step 3.

Locate the short to high. Disconnect connector X-ECC3B from connector X-ECC3A. Using a multi-meter, check for voltage between connector X-95 pin 9, or connector X-ECC3A pin 6 and ground. A.

If there is no voltage, there is a short to high source on wire 1023 (Blue) between connector X-ECC3B pin 9 and connector X-CN2B pin 2. Repair or replace the wire.

B.

If there is voltage, there is a short to high source on wire 1023 (Blue) between connector X-95 pin 9 and connector X-ECC3A pin 6. Repair or replace the wire.

Check for proper operation of the DRIVE PATTERN SELECTOR. Reconnect connector X-95 to the DRIVE PATTERN SELECTOR. Disconnect connector X-ECC3A from connector X-ECC3B. Using a multi-meter, check for voltage between connector X-ECC3A pin 6 and ground. A.

If voltage is greater than 8 V, the DRIVE PATTERN SELECTOR has failed. Replace the DRIVE PATTERN SELECTOR.

B.

If voltage is less than 8 V, continue with step 5.

Check for proper operation of the UCM. Reconnect connector X-CN2B to the UCM. Using a multi-meter, check for voltage between connector X-ECC3B pin 9 and ground. A.

If voltage is greater than 8 V, the UCM has failed. Replace the UCM. 84522361 15/06/2011

A.50.A / 371

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B. 6.

If voltage is less than 8 V, continue with step 6.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02) Wiring harness - Electrical schematic frame 06 (A.30.A.88-C.20.E.06)

84522361 15/06/2011

A.50.A / 372

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1903- UCM - UCM Supply Voltage Below Operational Limit L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCm Context: Diagnostic Trouble Code 1903 has an error priority of Red. All Hydraulics are disabled with Diagnostic Trouble Code 1903. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Blown fuse.

2.

Open wire in circuit.

3.

Shorted wire in circuit.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1903 - UCM - UCM Supply Voltage Below Operational Limit is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 6.

Check for blown fuse. Remove fuse F-6 from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Using a multimeter, check for resistance across the fuse. A.

If resistance is 0 Ω, continue with step 3.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for open circuit. Disconnect connector X-CN1A from the UCM. Using a multi-meter, check continuity between connector X-CN1A pin 20 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin C6. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 189 (Red) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin C6 and connector X-CN1A pin 20. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin C6 and ground. A.

If there is no continuity, continue with step 5.

B.

If there is continuity, there is a short to ground condition on wire 189 (Red) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin C6 and connector X-CN1A pin 20. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN1A-20 and CN1A-1. 84522361 15/06/2011

A.50.A / 373

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

6.

A.

If resistance is normal, continue with step 6.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)

84522361 15/06/2011

A.50.A / 374

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

1910- UCM - Rail 12VH - Ldr Plt Interlk & Port Lock Input Power OFF L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control Module : UCm Context: Diagnostic Trouble Code 1910 has an error priority of Red. Disable Loader Hydraulics is enabled with Diagnostic Trouble Code 1910. Cause: UCM has sensed that a 12 V UCM input has failed low. (The fault is only activated when Ignition is On, crank pin is low, Diagnostic Code 1903 is not active, and UCM input voltage is less than 9 V.) Possible failure modes: 1.

Blown fuse.

2.

Open wire in circuit.

3.

Shorted wire in circuit.

4.

Failure of UCM.

Solution: 1.

2.

3.

4.

5.

Before troubleshooting this Trouble Code electrically, ensure the battery and charging system are working properly. Due to the nature of the fault, and the design of the 12 VDC distribution system, this Trouble Code can be caused by a short in a number of different places. Use information regarding other active trouble codes to logically determine possible fault locations. This resolution procedure does not fully isolate the fault, it only tests the most likely components. Use the machine to recreate conditions for error. Use the EST to verify 1910 - UCM - Rail 12VH - Ldr Plt Interlk & Port Lock Input Power OFF is active. A.

If the fault is active, continue with step 2.

B.

If the fault is not active, the fault may be intermittent and not currently active, continue with step 8.

Check for blown fuse. Remove fuse F-25 from ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2. Using a multimeter, check for resistance across the fuse. A.

If resistance is 0 Ω, continue with step 3.

B.

If resistance is infinite, the fuse has blown. Replace with fuse of same type and amp rating.

Check for open circuit. Disconnect connector X-CN2A from the UCM. Using a multi-meter, check continuity between connector X-CN2A pin 7 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin C4. A.

If there is continuity, continue with step 4.

B.

If there is no continuity, there is an open wire condition on wire 182/159 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin C4 and connector X-CN2A pin 7. Repair or replace the wire.

Check for open circuit. Using a multi-meter, check continuity between connector X-CN2A pin 13 and ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin C4. A.

If there is continuity, continue with step 5.

B.

If there is no continuity, there is an open wire condition on wire 163 (Orange) between SPLICE 112 and connector X-CN2A pin 13. Repair or replace the wire.

Check for a short to ground. Using a multi-meter, check for continuity between connector ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin C4 and ground. A.

If there is no continuity, continue with step 6. 84522361 15/06/2011

A.50.A / 375

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES

B.

6.

7.

8.

If there is continuity, there is a short to ground condition on wire 182/159 (Orange) between ACCESSORY POWER DISTRIBUTION FUSE BLOCK 2 pin C4 and connector X-CN2A pin 7, or on wire 163 (Orange) between SPLICE 112 and connector X-CN2A pin 13. Repair or replace the wire.

Check for proper resistance of the UCM. Completely power down the UCM by removing all six connectors. Using a multi-meter, check for resistance between UCM pins CN2A-7 and CN1A-1. A.

If resistance is normal, continue with step 7.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Check for proper resistance of the UCM. Using a multi-meter, check for resistance between UCM pins CN2A-13 and CN1A-1. A.

If resistance is normal, continue with step 8.

B.

If resistance is 0 Ω, the UCM has shorted internally. Replace the UCM.

C.

If resistance is greater than 100 K Ω, the UCM has opened internally. Replace the UCM.

Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. Operate the machine while monitoring the EST and Display. Investigate nearby wiring. This Diagnostic Trouble Code resolution procedure does not completely rule out the UCM as a failure point. Therefore, all other possibilities should be investigated before the UCM is considered for replacement. A.

If damage is found or other than normal display readings are indicated, repair the damage discovered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved.

B.

If no damage or other than normal display readings are indicated, erase the Diagnostic Trouble Code and continue operation. Wiring harness - Electrical schematic frame 26 (A.30.A.88-C.20.E.26) Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)

84522361 15/06/2011

A.50.A / 376

Index HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A FAULT CODES - 50.A 1002- Engine Coolant Temperature Sender - Over Temperature >110° C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 1004- Hydraulic Filter Restriction Switch - Hydraulic Filter Restricted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 1009- Hydraulic Oil Temperature Sender - Over Temperature >210° F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 1014- Cluster Battery Monitor - Over Voltage > 16.5 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 1015-Cluster Battery Monitor - Under Voltage < 11.5 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 1025- Throttle Sensor - out of range STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1030- Throttle Sensor - out of range STG/OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1041- RPM Monitoring - Over Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 1045- Fuel Level Sensor - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 111-EGR potentiometer valve could not be completely opened . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L223, L225, L230, C227, C232, C238

112-EGR potentiometer valve could not be completely closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L223, L225, L230, C227, C232, C238

119-Engine crank signal present for 300 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L223, L225, L230, C227, C232, C238

1201- Hydraulic Filter Restriction Switch - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 1202- RPM Monitoring - Over Speed (Max) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 1203- RPM Monitoring - Open Circuit / STG / STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 1204- Start Sequence - Key Switch State - Engine Running Plausability Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 1205- Hydraulic Enable (EH Machines) - Hydraulic Enable Output - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1206- CAN Connection - Configuration Response Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1207- Memory Parameters - Invalid configuration between IC and UCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1208- Seat Switch - Plausibility Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1211- Calibration Functions - Joystick Calibration not Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1212- Calibration Functions - Ground Drive Calibration not Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 377

1213- Calibration Functions - Loader Valve Calibration not Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1214- Calibration Functions - Throttle Calibration not Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1221- Health Monitor Functions - UCM - UCM Temperature / Current Draw Over Limit . . . . . . . . . . . . . . . . . . . . 128 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1222- Health Monitor Functions - UCM - UCM Sustained Over Temperature Limit . . . . . . . . . . . . . . . . . . . . . . . . 129 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1223- Health Monitor Functions - UCM - UCM Sustained Over Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1224- Health Monitor Functions - UCM - Internal Memory or Core Monitoring Fault . . . . . . . . . . . . . . . . . . . . . . . 131 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1225- Health Monitor Functions - UCM - EEPROM Memory Checksum Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

126-Battery voltage fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L223, L225, L230, C227, C232, C238

131-Coolant temperature sensor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 L223, L225, L230, C227, C232, C238

134-Intake air pressure sensor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 L223, L225, L230, C227, C232, C238

1350- Hyd Ena switch - Implausible State (Hardwire vs CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

141-Engine speed sensor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 L223, L225, L230, C227, C232, C238

1511- Brake Lights - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

1512- Brake Lights - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

1513- Brake Lights - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

1521- Brake Lights - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

1522- Brake Lights - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

1523- Brake Lights - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

1532- Backup Alarm - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1533- Backup Alarm - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

186-EGR valve position sensor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 L223, L225, L230, C227, C232, C238

189-EGR valve position driver fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 L223, L225, L230, C227, C232, C238 84522361 15/06/2011

A.50.A / 378

1900- UCM - UCM Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1901- UCM - UCM Supply Voltage HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1902- UCM - UCM Supply Voltage LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1903- UCM - UCM Supply Voltage Below Operational Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1904- UCM - Rail 12VB - 5V regulators supply Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1905- UCM - 5VREF1 Sensor Supply Voltage Out of Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1906- UCM - 5VREF3 Sensor Supply Voltage Out of Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1907- UCM - Rail 12VF1 - Aux Retract Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1908- UCM - Rail 12VF2 - Bucket Extend Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1909- UCM - Rail 12VF3 - Boom Raise/Lower Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1910- UCM - Rail 12VH - Ldr Plt Interlk & Port Lock Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1911- UCM - Rail 12VH1 - Left & Right Pmp Reverse Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1912- UCM - Rail 12VM - Lft & Rgt Brake Lights & Aux Extend Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . 165 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1913- UCM - Rail 12VS1 - Bucket Curl Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1914- UCM - Rail 12VS2 - Backup Alarm Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1915- UCM - Rail 12VT1 - Two Speed Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1916- UCM - Rail 12VU1 - Right & Left Pumps Forward Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1917- UCM - Rail 12VU2 - Park Brake Solenoid Input Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1E5-Sensor voltage supply fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 L223, L225, L230, C227, C232, C238

2E5-Sensor ground fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 L223, L225, L230, C227, C232, C238 84522361 15/06/2011

A.50.A / 379

3000- Engine Malfunction - ECU Fault - General/Undefined/Air Filter Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 3007- Engine Coolant Temperature Sender - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 3008- Engine Coolant Temperature Sender - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 3028- Engine Oil Pressure Switch - Engine Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 3029- Engine Oil Pressure Switch - Engine Oil Pressure Switch OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 3154- Engine Preheat - Glow Plug - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 3156- Engine Preheat - Glow Plug - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 3401- Engine Start - Fuel Solenoid - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 3402- Engine Start - Fuel Solenoid - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 3403- Starter - Starter is cranked > 30s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 3404- Starter - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 3405- Starter - STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 4043- Hydraulic Oil Temperature Sender - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 4044- Hydraulic Oil Temperature Sender - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 4055- Park Brake Valve (On/Off) - Solenoid Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4056- Park Brake Valve (On/Off) - Solenoid Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4057- Park Brake Valve (On/Off) - Solenoid Supply STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4061- Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply OC . . . . . . . . . . . . . . . . . . . . . . . . 184 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4062- Forward Pump Control Valves (Directional) - Solenoid Right (A) Supply STG . . . . . . . . . . . . . . . . . . . . . . . 186 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4071- Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . 188 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4072- Forward Pump Control Valves (Directional) - Solenoid Left (B) Supply STG . . . . . . . . . . . . . . . . . . . . . . . . 190 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4081- Forward Pump Control Valves (Directional) - Common Solenoid Return STP . . . . . . . . . . . . . . . . . . . . . . . 192 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4082- Forward Pump Control Valves (Directional) - Pumps Forward Solenoids STG . . . . . . . . . . . . . . . . . . . . . . . 194 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4083- Forward Pump Control Valves (Directional) - Common Solenoid Return OC . . . . . . . . . . . . . . . . . . . . . . . . 196 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4309- Park Brake Button - Park Brake Button Timeout (30 sec) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4361-Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . 198 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 380

4362- Reverse Pump Control Valves (Directional) - Solenoid Right (A) Supply STG . . . . . . . . . . . . . . . . . . . . . . . 200 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4371- Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . 202 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4372- Reverse Pump Control Valves (Directional) - Solenoid Left (B) Supply STG . . . . . . . . . . . . . . . . . . . . . . . . 204 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4381- Reverse Pump Control Valves (Directional) - Common Solenoid Return STP . . . . . . . . . . . . . . . . . . . . . . . 206 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4382- Reverse Pump Control Valves (Directional) - Pumps Reverse Solenoids STG . . . . . . . . . . . . . . . . . . . . . . 208 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4383- Reverse Pump Control Valves (Directional) - Common Solenoid Return OC . . . . . . . . . . . . . . . . . . . . . . . . 210 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4401- Park Brake (Mechanical Machines) - Park Brake Solenoid - OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

4402- Park Brake (Mechanical Machines) - Park Brake Solenoid - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

4431- Park Brake Pressure Switch - Pressure Switch (plausibility check with solenoid valve) . . . . . . . . . . . . . . . 212 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4731- Right Swashplate angle sensor - Pin A STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4732- Right Swashplate angle sensor - Pin A STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4734- Right Swashplate angle sensor - Pin B STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4735- Right Swashplate angle sensor - Pin B STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4737- Right Swashplate angle sensor - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4741- Left Swashplate angle sensor - Pin A STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4742- Left Swashplate angle sensor - Pin A STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4744- Left Swashplate angle sensor - Pin B STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4745- Left Swashplate angle sensor - Pin B STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4747- Left Swashplate angle sensor - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

A.50.A / 381

4752- Left Swashplate angle sensor - Implausible command, command does not match with swashplate angle 232 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4754- Right Swashplate angle sensor - Implausible command, command does not match with swashplate angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4781- solenoid valve - Solenoid Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4782- solenoid valve - Solenoid Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4783- solenoid valve - Solenoid Supply STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

4951- Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid - STP . . . . . . . . . . . . . . . . . . . . . . . 98 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

4952- Hydraulic Enable (Mechanical Machines) - Hydraulic Interlock Solenoid - OC . . . . . . . . . . . . . . . . . . . . . . . 100 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

5051- Loader Pilot Interlock Valve (On/Off) - Solenoid Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5052- Loader Pilot Interlock Valve (On/Off) - Solenoid Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5053- Loader Pilot Interlock Valve (On/Off) - Solenoid Supply STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5061- Port Lock Valve (On/Off) - Solenoid Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5062- Port Lock Valve (On/Off) - Solenoid Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5063- Port Lock Valve (On/Off) - Solenoid Supply STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5121-R joy F-B axis - Pin A STP / STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5122- R joy F-B axis - Pin B STP / STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5124- R joy F-B axis - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5131- R joy R-L axis (ISO/H Pattern) - Pin A STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5132- R joy R-L axis (ISO/H Pattern) - Pin A STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5134- R joy R-L axis (ISO/H Pattern) - Pin B STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls 84522361 15/06/2011

A.50.A / 382

5135- R joy R-L axis (ISO/H Pattern) - Pin B STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5137- R joy R-L axis (ISO/H Pattern) - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5141- Aux thumbwheel axis - Pin A STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5142- Aux thumbwheel axis - Pin A STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5144- Aux thumbwheel axis - Pin B STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5145-Aux thumbwheel axis - Pin B STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5147- Aux thumbwheel axis - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5201- L joystick L-R axis - Pin A STP / STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5202- L joystick L-R axis - Pin B STP / STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5204-L joystick L-R axis - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5211- L joy F-B axis - Pin A STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5212- L joy F-B axis - Pin A STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5214-L joy F-B axis - Pin B STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5215- L joy F-B axis - Pin B STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5217- L joy F-B axis - in-range fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5221- Loader Arm Valve (Directional) - Solenoid Raise A Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5222- Loader Arm Valve (Directional) - Solenoid Raise A Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5231- Loader Arm Valve (Directional) - Solenoid Lower B Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5232- Loader Arm Valve (Directional) - Solenoid Lower B Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls 84522361 15/06/2011

A.50.A / 383

5241- Boom Valve (Directional) - Common Solenoid (C) Return STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5242- Loader Arm Valve (Directional) - Loader Arm Solenoids STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5243- Boom Valve (Directional) - Common Solenoid (C) Return OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5251- Loader Bucket Valve (Directional) - Solenoid rollback (A) Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5252- Loader Bucket Valve (Directional) - Solenoid rollback (A) Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5261- Bucket Valve (Directional) - Solenoid dump (B) Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5262- Bucket Valve (Directional) - Solenoid dump (B) Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5271- Bucket Valve (Directional) - Common Solenoid (C) Return STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5272- Loader Bucket Valve (Directional) - Loader Bucket Solenoids STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5273- Bucket Valve (Directional) - Common Solenoid (C) Return OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5281- Aux Valve (Directional) - Solenoid Forward (A) Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5282- Aux Valve (Directional) - Solenoid Forward (A) Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5291- Aux Valve (Directional) - Solenoid Reverse (B) Supply OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5292- Aux Valve (Directional) - Solenoid Reverse (B) Supply STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5309- Float Button - Float Button Timeout (30 sec) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5409- CAN Message Error - Aux Override Disabled due to Aux Override Button Timeout (30 sec) . . . . . . . . . . 329 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5501- Loader Arm Spool Sensor - Sensor STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5502- Loader Arm Spool Sensor - Sensor STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5503- Hydraulic Enable (Mechanical Machines) - EH AUX Output - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls 84522361 15/06/2011

A.50.A / 384

5504- Bucket Valve Spool sensor - Sensor STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5505- Bucket Valve Spool sensor - Sensor STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5507-Auxiliary Valve Spool Sensor - Sensor STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5508- Auxiliary Valve Spool Sensor - Sensor STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5511- Loader Arm Spool Sensor - implausible state sensor vs loader arm command, stuck spool/PRV . . . . . . 342 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5512- Bucket Valve Spool sensor - implausible state sensor vs loader bucket command . . . . . . . . . . . . . . . . . . . 344 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5513- Auxiliary Valve Spool Sensor - implausible state sensor vs auxiliary command . . . . . . . . . . . . . . . . . . . . . . 346 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5601- Aux Valve (Directional) - Common Solenoid Return STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5602- Loader Auxiliary Valve (Directional) - Loader Auxiliary Solenoids STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5603- Loader Auxiliary Valve (Directional) - Solenoids Return OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5701- Pattern Switch - STG / OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5703- Pattern Switch - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

5811- switch - implausible state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 L213 WE Electro hydraulic controls, L215 WE Electro hydraulic controls, L218 WE Electro hydraulic controls, L220 WE Electro hydraulic controls, L223 WE Electro hydraulic controls, L225 WE Electro hydraulic controls, L230 WE Electro hydraulic controls, C227 WE Electro hydraulic controls, C232 WE Electro hydraulic controls, C238 WE Electro hydraulic controls

9003- CAN - J1939 Receive Buffer - Buffer Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 9004- Memory Error - Triple Redundant - Hour Meter - Location 1 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 9005- Memory Error - Triple Redundant - Hour Meter - Location 2 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 9006- Memory Error - Triple Redundant - Hour Meter - Location 3 Corrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 9151- CAN Connection - CAN communication timed out after 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

9152-CAN connection - CAN communication timed out after 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

9158- H pattern indicator - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

9159- ISO pattern indicator - STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls 84522361 15/06/2011

A.50.A / 385

9160- H pattern indicator - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

9161- ISO pattern indicator - STP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

9401- Memory Error - Double Redundant - Memory Corruption Detected and repaired . . . . . . . . . . . . . . . . . . . . 108 9403- Memory Error - Double Redundant - Un-recoverable memory corruption operable . . . . . . . . . . . . . . . . . . . 109 9404- Memory Error - Triple Redundant - Hour Meter - Hour Meter Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 9405- CAN - DM1 (EH Machines) - Loss of DM1 message from UCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

9406- CAN - Can Communication Lost (EH Machines) - Loss of all can communication from UCM . . . . . . . . . . 114 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

9407- Memory Error - ID Errors - Unrecoverable Hardware ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 9408- Memory Error - ID Errors - Unrecoverable Panel ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

84522361 15/06/2011

A.50.A / 386

84522361 15/06/2011

A.50.A / 387

New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

84522361 15/06/2011 EN

SERVICE MANUAL ENGINE AND PTO IN

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

B

Contents ENGINE AND PTO IN - B

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

B

ENGINE AND PTO IN - B ENGINE - 10.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

B.10.A / 1

Contents ENGINE AND PTO IN - B ENGINE - 10.A

SERVICE ENGINE Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L213, L215, L218, L220

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 L223, L225, L230, C227, C232, C238

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 L223, L225, L230, C227, C232, C238

84522361 15/06/2011

B.10.A / 2

ENGINE AND PTO IN - ENGINE

ENGINE - Remove L213, L215, L218, L220

Prior operation: Tilt system - Tilt (E.34.A). Prior operation: Battery - Disconnect (A.30.A). 1.

2.

3.

Remove the hood strut (1) from hood

931001682

1

931002025

2

931002026

3

Remove hood mounting hardware (2) from left and right hand side

Remove the hood (3).

4.

Remove the rear access door refer to Engine hood - Remove (E.20.A).

5.

Drain the engine oil.

6.

Remove the radiator refer to Radiator - Remove (B.50.A).

7.

Remove the oil cooler refer to Oil cooler - Remove (A.10.A).

84522361 15/06/2011

B.10.A / 3

ENGINE AND PTO IN - ENGINE

8.

9.

10.

11.

Remove the four mounting bolts (4) and slide the fan off the hub.

931002027

4

931002028

5

931002029

6

931002030

7

Remove the five mounting bolts (5) retaining the muffler inlet pipe mounting flange to the turbocharger and remove muffler.

Remove the two retaining bolts (6) from the muffler support.

Disconnect air restriction sensor (7).

84522361 15/06/2011

B.10.A / 4

ENGINE AND PTO IN - ENGINE

12.

13.

14.

15.

Loosen the hose clamps on the intake tube at both ends, remove the intake tube (8), cover turbocharger inlet to avoid entry of debris.

931002031

8

931002032

9

Remove air cleaner housing (9).

Loosen hose clamp and remove upper radiator hose (10) from engine.

931002033

10

931002034

11

Disconnect the glow plug connection (11). Remove wire clamp (12).

84522361 15/06/2011

B.10.A / 5

ENGINE AND PTO IN - ENGINE

16.

17.

18.

19.

Disconnect the starter connections (13).

931002035

12

931002036

13

931002037

14

931002038

15

Disconnect the alternator connection (14).

Disconnect temperature sender wire (15).

Disconnect oil pressure sender wire (16) and wire clamp (17).

84522361 15/06/2011

B.10.A / 6

ENGINE AND PTO IN - ENGINE

20.

21.

22.

23.

Disconnect throttle cable by removing the nut (A)and bolt (B) from the throttle body. Remove cable support clamp (C) by loosening the two hex head bolts (D).

931002039

16

931002040

17

931002042

18

931002041

19

Disconnect wire harness (18) and clamps (19) from the top of the flywheel housing.

Place a suitable container under lines to prevent spillage and remove the fuel supply line (20).

Remove the fuel return line (21).

84522361 15/06/2011

B.10.A / 7

ENGINE AND PTO IN - ENGINE

24.

25.

Disconnect the spade connector (E)from the back side of the fuel shut off solenoid.

931002043

20

931002044

21

931002045

22

931002046

23

Place a suitable container under the remote engine oil filter lines. Label and disconnect oil filter lines (22).

NOTE: Cap the ends to avoid entry of debris.

26.

27.

Disconnect the ground from the engine (23) to the battery quick disconnect.

Remove the twelve mounting bolts (24) securing the hydraulic pump to the engine plate

84522361 15/06/2011

B.10.A / 8

ENGINE AND PTO IN - ENGINE

28.

29.

30.

31.

Remove engine oil pan drain hose clamp (F).

931002050

24

931002047

25

931002048

26

931002049

27

Remove the front engine mounts (25).

Remove the rear engine mount (26).

Remove the four mounting bolts (27) from the fixed hood, remove hood.

84522361 15/06/2011

B.10.A / 9

ENGINE AND PTO IN - ENGINE

32.

33.

34.

Place a suitable support beam across the skid steer frame. Tie a suitable strap around the pump and secure to the support beam, as shown.

931002051

28

931002052

29

931002053

30

Attach proper lifting straps to the eye hooks (28) provided on the engine.

Use a suitable hoist to carefully lift the engine slightly rearward to separate from the hydraulic pumps. Once free, lift the engine and remove from the rear of chassis.

84522361 15/06/2011

B.10.A / 10

ENGINE AND PTO IN - ENGINE

ENGINE - Remove L223, L225, L230, C227, C232, C238

WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine. 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in death or serious injury. W0047A

WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A

WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Prior operation: Tilt system - Tilt (E.34.A). Prior operation: Battery - Disconnect (A.30.A). Prior operation: Radiator - Remove (B.50.A)

84522361 15/06/2011

B.10.A / 11

ENGINE AND PTO IN - ENGINE

1.

2.

Remove the hood struts (1) from each side by gently prying the retaining clip (2) just enough to release the strut.

1

931002025

2

931002026

3

931001896

4

Remove hood mounting hardware (1) from left-hand and right-hand side of the hood.

3.

Remove the hood (1).

4.

Remove the rear access door refer to Engine hood - Remove (E.20.A).

5.

Remove the oil cooler refer to Oil cooler - Remove (A.10.A).

6.

931001887

Remove the three mounting bolts (1) retaining the muffler inlet pipe mounting flange to the turbocharger, cover turbocharger inlet the avoid entry of debris.

84522361 15/06/2011

B.10.A / 12

ENGINE AND PTO IN - ENGINE

7.

8.

9.

10.

Remove the four retaining bolts (1) from the muffler support.

931001895

5

931002030

6

931001898

7

931001899

8

Disconnect air restriction sensor (1).

Loosen the hose clamps on the intake tube at both ends, remove the air cleaner to turbo charger tube (1).

Remove the engine cover (1).

84522361 15/06/2011

B.10.A / 13

ENGINE AND PTO IN - ENGINE

11.

Remove air cleaner housing (1) by removing the three bolts (2).

931001900

12.

13.

14.

9

Loosen hose clamp (1) and remove upper radiator hose (2) from engine.

931001903

10

931001908

11

931001909

12

Disconnect the alternator electrical connections (1).

Disconnect the starter electrical connections (1).

84522361 15/06/2011

B.10.A / 14

ENGINE AND PTO IN - ENGINE

15.

16.

17.

Disconnect ground connection (1) below the starter (2).

931001910

13

931001911

14

931002113

15

Unplug wire harness connection (1).

Disconnect low pressure line (1) from the Air-conditioning compressor (2).

NOTE: Place a suitable container under the machine to catch any lost fuel.

84522361 15/06/2011

B.10.A / 15

ENGINE AND PTO IN - ENGINE

18.

WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately. Failure to comply could result in death or serious injury. W0099A

WARNING

931001917

16

931001919

17

931001922

18

Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A

Remove the fuel return line (1). 19.

20.

Remove the fuel supply line (1).

Remove the throttle cable (1).

84522361 15/06/2011

B.10.A / 16

ENGINE AND PTO IN - ENGINE

21.

22.

23.

24.

Place a suitable container under the remote engine oil filter lines (1). Label and disconnect oil filter lines.

931001923

19

931002046

20

931001925

21

931001926

22

Remove the twelve mounting bolts (24) securing the hydraulic pump to the engine plate

Disconnect fuel pump electrical connection (1).

Disconnect harness (1) from connector (2).

84522361 15/06/2011

B.10.A / 17

ENGINE AND PTO IN - ENGINE

25.

26.

27.

28.

Place a suitable support beam (1) across the skid steer frame. Tie a suitable strap (2) around the pump (3) and secure to the support beam, as shown.

931001929

23

931001928

24

931001936

25

931001944

26

Remove the two pump mounting bolts (1).

Disengage pump assembly (1) from engine housing (2).

DANGER Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply will result in death or serious injury. D0018A

Attach proper lifting straps (1) to support the engine (2).

84522361 15/06/2011

B.10.A / 18

ENGINE AND PTO IN - ENGINE

29.

30.

31.

32.

Remove the front and rear engine mounts (1).

931001933

27

931001938

28

931002050

29

931001943

30

Raise the engine slightly as shown.

Remove engine oil drain hose clamp (1).

Remove heater hose clamp (1).

84522361 15/06/2011

B.10.A / 19

ENGINE AND PTO IN - ENGINE

33.

Remove upper heater hose (1).

NOTE: Use a suitable device to catch any coolant not drained previously.

34.

35.

931002114

31

931001940

32

931001946

33

Remove lower heater hose (1).

WARNING Heavy object! ALWAYS use adequate lifting equipment (heavy-duty hoist, loader, or forklift) to lift the component. Failure to comply could result in death or serious injury. W0101A

Remove engine (1) from the chassis.

84522361 15/06/2011

B.10.A / 20

ENGINE AND PTO IN - ENGINE

ENGINE - Install 1.

2.

Attach proper lifting straps to the eye hooks (1) provided on the front right and rear left of the engine.

931002052

1

931002053

2

931002046

3

Using a suitable hoist carefully lower engine into engine compartment on the skid steer.

3.

Slowly orient the hydraulic pump coupler to the adapter on the engine ensuring the attachment of engine plate to flywheel housing.

4.

Attach engine to hydraulic pump mounting plate using the twelve mounting bolts (2).

84522361 15/06/2011

B.10.A / 21

ENGINE AND PTO IN - ENGINE

5.

6.

7.

8.

Remove support brace and straps from hydraulic pump.

931002051

4

931002047

5

931002048

6

931002049

7

Install front engine mounting bolts (3).

Install rear engine mounting bolt (4).

Install Fixed hood and secure with hardware (5).

84522361 15/06/2011

B.10.A / 22

ENGINE AND PTO IN - ENGINE

9.

10.

11.

12.

Install engine oil pan drain hose into clamp (6).

931002050

8

931002045

9

Connect ground from the quick battery disconnect to the engine (7).

Connect remote engine oil filter lines (8).

931002044

10

931002043

11

Connect the spade connector to the back of the fuel shut off solenoid (9).

84522361 15/06/2011

B.10.A / 23

ENGINE AND PTO IN - ENGINE

13.

14.

15.

16.

Connect the fuel return line (10).

931002041

12

931002042

13

931002040

14

931002039

15

Connect the fuel supply line (11).

Connect the wire harness (12) and clamps (13) to the top of the flywheel housing..

Connect throttle cable by installing the nut (A)and bolt (B) to the throttle body. Install cable support clamp (C) and tighten the two hex head bolts (D).

84522361 15/06/2011

B.10.A / 24

ENGINE AND PTO IN - ENGINE

17.

18.

19.

20.

Connect oil pressure sender wire (14) and support (15).

931002038

16

931002037

17

931002036

18

931002035

19

Connect temperature sensor wire (16).

Connect alternator connection (17).

Connect starter connections (18).

84522361 15/06/2011

B.10.A / 25

ENGINE AND PTO IN - ENGINE

21.

22.

23.

24.

Connect glow plug connection (19) and wire clamp (20).

931002034

20

931002033

21

931002032

22

931002031

23

Install upper radiator hose (21) to engine and tighten hose clamp.

Install air cleaner housing to bracket, secure with mounting bolts (22).

Install air cleaner to turbo hose (23) and tighten hose clamp.

84522361 15/06/2011

B.10.A / 26

ENGINE AND PTO IN - ENGINE

25.

26.

27.

28.

Connect air restriction sensor (24).

931002030

24

931002028

25

931002029

26

931002027

27

Install muffler inlet pipe mounting flange to turbocharger and secure with the five mounting bolts (25).

Install the two retaining bolts (26) to the muffler support.

Place fan on hub and secure with the four retaining bolts (A).

29.

Install oil cooler refer to Oil cooler - Install (A.10.A).

30.

Install radiator refer to Radiator - Install (B.50.A).

31.

Add engine oil. 84522361 15/06/2011

B.10.A / 27

ENGINE AND PTO IN - ENGINE

32.

Fill hydraulic oil reservoir refer to Reservoir - Filling (A.10.A).

33.

Fill coolant refer to Radiator - Filling (B.50.A).

34.

Lift engine hood into place on the top of the skid steer.

35.

36.

931002026

28

931002025

29

931001682

30

Install the left and right hand side hood mounting bolts (27).

Connect the hood support strut (B) to the left hand side of hood.

37.

Install rear access door refer to Engine hood - Install (E.20.A).

38.

Lower cab refer to Tilt system - Lower (E.34.A).

84522361 15/06/2011

B.10.A / 28

ENGINE AND PTO IN - ENGINE

ENGINE - Install L223, L225, L230, C227, C232, C238

1.

2.

3.

4.

Attach proper lifting straps to the eye hooks provided on the front and rear of the engine, as shown.

931001946

1

931001944

2

931001936

3

931001928

4

Using a suitable hoist carefully lower engine into engine compartment on the skid steer.

Carefully orient hydraulic pump coupler to adapter on the engine ensuring attachment of engine plate to flywheel housing.

Install pump mounting bolts and washers (1) into pump housing.

84522361 15/06/2011

B.10.A / 29

ENGINE AND PTO IN - ENGINE

5.

6.

7.

8.

Install the two rear engine mounting bolts and bushings (2).

931001933

5

931002047

6

931001929

7

931001940

8

Install the two front engine mounting bolts and bushings (3).

Verify pump mounting bolts are secure and carefully remove support brace (4)and straps (5) from pump.

Connect the lower heater hose (6).

84522361 15/06/2011

B.10.A / 30

ENGINE AND PTO IN - ENGINE

9.

Connect the upper heater hose (7).

931002114

10.

11.

12.

9

Attach heater hose support clamp (8).

931001943

10

931002050

11

931001926

12

Attach engine oil pan drain hose support clamp (9).

Connect the wiring harness connection (10).

84522361 15/06/2011

B.10.A / 31

ENGINE AND PTO IN - ENGINE

13.

14.

15.

16.

Connect the fuel pump wire connection (11).

931001925

13

931001923

14

931001922

15

931001919

16

Connect the two remote oil filter lines (12) and (13) as previously labeled.

Connect throttle cable by installing the nut (A) and bolt (B) to the throttle body. Install cable support clamp and tighten the two hex head bolts (C).

Connect fuel supply line (14).

84522361 15/06/2011

B.10.A / 32

ENGINE AND PTO IN - ENGINE

17.

18.

19.

20.

Connect fuel return line (15).

931001917

17

931002113

18

931001911

19

931001910

20

Connect low pressure line to the air condition compressor (16).

Connect wire harness connection (17) located on left hand side above motor mount.

Connect the ground to engine from battery quick disconnect (18) and cab ground (19).

84522361 15/06/2011

B.10.A / 33

ENGINE AND PTO IN - ENGINE

21.

22.

23.

24.

Connect the two starter connections (D) and (E).

931001909

21

931001908

22

931001903

23

931001900

24

Connect the two alternator connections (F) and (G).

Install upper radiator hose (20) to engine and tighten hose clamp.

Install the three mounting bolts (21) that secure air cleaner housing and bracket to frame.

84522361 15/06/2011

B.10.A / 34

ENGINE AND PTO IN - ENGINE

25.

26.

27.

28.

Install the fixed hood and secure with hardware (22).

931001899

25

931001898

26

931001897

27

931001895

28

Connect air cleaner to turbo hose (23).

Connect air restriction sensors electrical connection (24).

Install the four mounting bolts from the muffler brackets (25).

84522361 15/06/2011

B.10.A / 35

ENGINE AND PTO IN - ENGINE

29.

30.

31.

32.

Install the three retaining bolts (26) to the exhaust manifold mounting flange .

931001896

29

931001894

30

931001887

31

931001887

32

Attach lifting straps through the engine hood and hoist in mounting location.

Install left and right hand side hood mounting hardware (27).

Connect left and right hand side hood struts (28).

84522361 15/06/2011

B.10.A / 36

ENGINE AND PTO IN - ENGINE

33.

34.

35.

Connect condenser fan electrical connection (29).

931001893

33

931001890

34

931001889

35

Connect top and bottom air condition condenser lines (30).

Install air condition refrigerant.

Next operation: Oil cooler - Install (A.10.A). Next operation: Radiator - Install (B.50.A). Next operation: Reservoir - Filling (A.10.A). Next operation: Radiator - Filling (B.50.A). Next operation: Tilt system - Lower (E.34.A).

84522361 15/06/2011

B.10.A / 37

Index ENGINE AND PTO IN - B ENGINE - 10.A ENGINE - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ENGINE - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 L223, L225, L230, C227, C232, C238

ENGINE - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L213, L215, L218, L220

ENGINE - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 L223, L225, L230, C227, C232, C238

84522361 15/06/2011

B.10.A / 38

ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

B.20.A / 1

Contents ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A

TECHNICAL DATA Sensing system General specification Resistance Fuel Bar Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Throttle command Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fuel tank Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Sensing system Level sensor - Remove Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Level sensor - Install Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

84522361 15/06/2011

B.20.A / 2

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Sensing system - General specification Resistance Fuel Bar Conversion Resistance Fuel Bar Conversion for Large Machines Resistance Low (in Ω) < 32 33 68 108 155 188 211 243

Resistance High (in Ω) 32 67 107 154 187 210 242 > 243

Bars 8 7 6 5 4 3 2 1

Resistance Fuel Bar Conversion for Medium Machines Resistance Low (in Ω) < 32 33 48 88 132 155 201 231

Resistance High (in Ω) 32 47 87 131 154 200 230 > 231

Bars 8 7 6 5 4 3 2 1

Resistance Fuel Bar Conversion for Small Machines Resistance Low (in Ω) 86 80 73 66 55 38 16 0

Resistance High (in Ω) > 86 85 79 72 65 54 37 15

84522361 15/06/2011

B.20.A / 3

Bars 8 7 6 5 4 3 2 1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Throttle command - Adjust 1.

2.

3.

Start the machine. Press and Hold Auxiliary Over Ride Button (1) for 2 seconds. Release button, and press to toggle (2) to next display setting. Continue to press and release button until RPM’s are displayed

931007504

1

93111552

2

93111549

3

Adjust the clevis (1) on the end of the foot pedal, so that with the first 5 degrees of handle movement the pedal starts to move. If the pedal does not move with the throttle handle, turn the clevis in to shorten the cable.

Loosen the jam nut (1), turn the stop bolt (2) IN several turns.

NOTE: Make sure the plunger is through the L-Bracket when the jam nut is tight. Plunger must move freely through L-bracket . Do not pinch the L-Bracket between plunger and washer. 4.

Place engine throttle in low idle position to adjust cable length on the engine. Turn the plunger thumb screw (1) in until cable (2) is fairly tight. If cable is too tight, the engine will not return to low idle. Idle should be approximately 1075 RPM +/- 75 RPM.

93111551

84522361 15/06/2011

B.20.A / 4

4

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

5.

6.

Move hand throttle (1) to full position. Full throttle should be approximately 2675 RPM +/- 75 RPM.

93111550

5

93111549

6

Turn stop bolt (1) OUT until is contacts the pedal. Tighten the jam nut (2).

84522361 15/06/2011

B.20.A / 5

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel tank - Remove Prior operation: ENGINE - Remove (B.10.A) 1.

2.

3.

Disconnect the fuel sender connector (1).

931002098B

1

931002098B

2

931002099B

3

Label and disconnect fuel supply line (2).

Remove left hand side fuel tank bracket (3).

84522361 15/06/2011

B.20.A / 6

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

4.

Remove right hand side fuel tank bracket (4).

5.

Drain fuel from the tank using the drain plug located at the bottom of the tank.

6.

Remove fuel tank.

84522361 15/06/2011

B.20.A / 7

931002100B

4

931002102B

5

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel tank - Install 1.

2.

Position fuel tank into correct location on skid steer.

931002102B

1

931002099B

2

Install left hand side fuel tank bracket (1).

84522361 15/06/2011

B.20.A / 8

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

3.

4.

5.

6.

Install right hand side fuel tank bracket (2).

931002100B

3

931002098B

4

931002098B

5

Connect fuel supply line (3).

Connect fuel sender (4).

Install engine refer to ENGINE - Install (B.10.A).

84522361 15/06/2011

B.20.A / 9

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Sensing system Level sensor - Remove Fuel Level Sender 1.

2.

3.

4.

Locate and open rear engine hood (1).

93107449

1

931002032

2

931002098

3

931002098

4

Remove hardware (1) from air filter housing (2).

Disconnect connector X-14 (1) from the fuel level sender B-001 (2).

Label and disconnect the fuel lines (1).

84522361 15/06/2011

B.20.A / 10

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

5.

6.

Remove hardware (1) and fuel level sender retainer (2).

931002098

5

931002098

6

Remove fuel level sender B-001 (1) from fuel tank.

84522361 15/06/2011

B.20.A / 11

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Sensing system Level sensor - Install Fuel Level Sender 1.

2.

3.

4.

Insert fuel level sender B-001 (1) into the fuel tank.

93111533

1

93111534

2

931002098

3

931002098

4

Place the fuel level sender retainer (1), and hardware (2) onto fuel tank. Tighten hardware.

Reconnect the fuel lines (1).

Reconnect connector X-14 (1) to the fuel level sender B-001 (2).

84522361 15/06/2011

B.20.A / 12

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

5.

6.

Install air filter housing (1) and bolts (2). Tighten the bolts.

931002032

5

93107449

6

Close rear engine hood (1).

84522361 15/06/2011

B.20.A / 13

Index ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sensing system - General specification Resistance Fuel Bar Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sensing system Level sensor - Install Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Sensing system Level sensor - Remove Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Throttle command - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84522361 15/06/2011

B.20.A / 14

ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

B.30.A / 1

Contents ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A

SERVICE Sensing system Air cleaner restriction - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air cleaner restriction - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84522361 15/06/2011

B.30.A / 2

ENGINE AND PTO IN - AIR INTAKE SYSTEM

Sensing system Air cleaner restriction - Remove 1.

2.

3.

4.

Locate and open rear engine hood (1) and service door (2).

93107449A1

1

931002032

2

931002030

3

931002030

4

Remove hardware (1) from air filter housing (2).

Remove hose clamp (1) from air cleaner assembly (2).

Remove clip (1) securing connector X-508. Disconnect connector X-508 from the air filter restriction switch B-016 (2).

84522361 15/06/2011

B.30.A / 3

ENGINE AND PTO IN - AIR INTAKE SYSTEM

5.

Unscrew the air filter restriction switch B-016 (1) by hand from air cleaner assembly (2).

931002030

84522361 15/06/2011

B.30.A / 4

5

ENGINE AND PTO IN - AIR INTAKE SYSTEM

Sensing system Air cleaner restriction - Install 1.

2.

3.

4.

Install the air filter restriction switch (1) into the air cleaner assembly.

931002030

1

931002030

2

931002030

3

931002032

4

Connect the connector (1) to the air filter switch, and insert clip (2).

Place hose clamp (1) over hose and connect to air cleaner assembly (2). Tighten the hose clamp.

Insert hardware (1), and attach air cleaner assembly (2) to mount.

84522361 15/06/2011

B.30.A / 5

Index ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A Sensing system Air cleaner restriction - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sensing system Air cleaner restriction - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

B.30.A / 6

ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

B.50.A / 1

Contents ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A

SERVICE Radiator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

84522361 15/06/2011

B.50.A / 2

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Radiator - Remove Prior operation: Radiator - Drain fluid (B.50.A). 1.

2.

3.

4.

Disconnect the radiator over-flow hose, (1), at the radiator and elevate above the overflow reservoir allowing fluid to drain into over-flow. Hose can be draped anywhere it is save from damage.

931001645

1

931001648

2

931001650

3

931001653

4

Loosen the hose clamp and remove the upper radiator hose from the radiator (2).

Loosen the top mounting bolts from both left hand side and right hand side of radiator (3).

Tilt the top of the radiator out, as shown.

84522361 15/06/2011

B.50.A / 3

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

5.

6.

7.

Loosen the hose clamp and disconnect lower radiator hose (4).

931002071

5

931002060

6

931002061

7

931002062

8

Remove the two radiator support clips (5) from the support pins on the right hand side of bracket. Push the support pins out.

Remove left hand side support hardware (6) from the bottom of the bracket.

84522361 15/06/2011

B.50.A / 4

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

8.

Remove radiator along with left hand side bracket.

931001654

84522361 15/06/2011

B.50.A / 5

9

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Radiator - Install 1.

2.

3.

Slide radiator back in right hand side mounting bracket (1).

931001654

1

931002062

2

931002071

3

Install left hand side bracket support hardware (2).

Tilt radiator out and connect lower radiator hose (3) and tighten hose clamp.

84522361 15/06/2011

B.50.A / 6

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

4.

5.

6.

Push right hand side radiator support pins through bracket and install retaining clips (4).

931002060

4

931002061

5

931001653

6

931001650

7

Tilt radiator in and align top brackets.

Tighten top mounting bolts (5) on both left and right hand side.

84522361 15/06/2011

B.50.A / 7

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

7.

8.

9.

Connect the upper radiator hose (6) to the radiator and tighten hose clamp.

931001648

8

931001645

9

Connect over flow hose (7).

After the radiator has been installed refer to the following procedure for filling the radiator. Radiator Filling (B.50.A).

84522361 15/06/2011

B.50.A / 8

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Radiator - Remove Prior operation: Radiator - Drain fluid (B.50.A). 1.

2.

3.

4.

Locate the radiator drain (1) on the lower left hand side of the of the radiator and connect a hose. Place a suitable bucket under the hose to retain the antifreeze. Turn the drain valve counter-cloclwise to open drain.

931001849

1

931001851

2

931001854

3

931001856

4

Disconnect the radiator over-flow hose (2) from radiator and elevate hose allowing fluid to drain into over-flow tank. Hose can now be draped anywhere it is safe from damage..

Loosen the hose clamp and remove the upper radiator hose (3) from radiator.

Loosen the left and right hand side top radiator mounting bolts (4).

84522361 15/06/2011

B.50.A / 9

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

5.

6.

7.

8.

Tilt the top of the radiator out, as shown.

931001857

5

931001859

6

931001860

7

931001864

8

Loosen the hose clamp and remove lower radiator hose (5) from radiator.

Remove the two radiator support clips (6) from the support pins and pull pins out.

Lift the radiator up and out of the skid steer, as shown.

84522361 15/06/2011

B.50.A / 10

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Radiator - Install 1.

2.

3.

Lower the radiator into the mounting brackets, as shown.

931001864

1

931001863

2

931001860

3

931001857

4

Insert the radiator support pins through the bracket and radiator and secure with support clips (1).

Tilt the top of the radiator out, as shown.

84522361 15/06/2011

B.50.A / 11

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

4.

5.

6.

7.

8.

Connect the lower radiator hose (2) and tighten hose clamp.

931001858

5

931001856

6

931001853

7

931001850

8

Tilt the top of the radiator back in and secure both sides with the top mounting bolts (3).

Connect the upper radiator hose (4) to the radiator and tighten hose clamp.

Connect the radiator over flow hose (5) to the radiator.

Fill the radiator to correct level refer to Radiator Filling (B.50.A).

84522361 15/06/2011

B.50.A / 12

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Radiator - Drain fluid 1.

If engine is HOT do not drain cooling system. Allow the system to cool before draining the radiator.

2.

Open the rear access door.

3.

Drain the engine coolant system by loosening the drain valve (1), and drain the coolant into a suitable container. When the radiator is empty, tighten the drain valve

931001644

84522361 15/06/2011

B.50.A / 13

1

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Radiator - Filling CAUTION Burn hazard! Take care if removing the filler cap while the system is hot. Before removing the cap: completely cover the cap using a thick cloth, and slowly open the filler cap to allow the pressure to escape. Do not add cold water to a hot coolant reservoir. Failure to comply could result in minor or moderate injury. C0031A

1.

2.

3.

Open the rear access door and remove the radiator cap (1) after the engine has cooled.

931001652

1

931001645

2

Fill the radiator with a 50% mixture of ethylene glycol engine coolant and 50% water mixture. The coolant level must be to the top of the radiator fill neck, just below the overflow tube (1). Install cap loosely (2).

Start and run the engine until it reaches operating temperature. Stop the engine and check the level of the coolant in the recovery bottle (2). Fill the recovery bottle with a 50% mixture of ethylene glycol engine coolant and 50% water mixture to the full level marked on the bottle. Once level is good tighten cap.

NOTICE: Do not remove the radiator cap from the radiator while the engine is HOT.

84522361 15/06/2011

B.50.A / 14

Index ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A Radiator - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Radiator - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

84522361 15/06/2011

B.50.A / 15

84522361 15/06/2011

B.50.A / 16

ENGINE AND PTO IN - B STARTING SYSTEM - 80.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

B.80.A / 1

Contents ENGINE AND PTO IN - B STARTING SYSTEM - 80.A

FUNCTIONAL DATA Cold start aid Overview Engine preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DIAGNOSTIC Start control Testing Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84522361 15/06/2011

B.80.A / 2

ENGINE AND PTO IN - STARTING SYSTEM

Cold start aid - Overview Engine preheat During cold starts, diesel engine preheating is completed by the use of glow plugs. Engines use glow-plugs in each combustion chamber to increase the temperature of the cylinder. Diesel engines rely solely on compression to raise the temperature of the air to a point where the diesel will combust spontaneously when introduced to the hot high pressure air. At normal temperature, the high pressure and spray pattern of the diesel ensures a controlled, complete burn. The piston rises, compressing the air in the cylinder; this causes the air's temperature to rise. By the time the piston reaches the top of its travel path, the temperature in the cylinder is very high. The fuel mist is then sprayed into the cylinder; it instantly combusts, forcing the piston downwards, thus generating power.

84522361 15/06/2011

B.80.A / 3

ENGINE AND PTO IN - STARTING SYSTEM

Start control - Testing Ignition Switch NOTE: Wiring Wiring Wiring

Use schematics harness - Electrical schematic frame 03 (A.30.A) harness - Electrical schematic frame 04 (A.30.A) harness - Electrical schematic frame 14 (A.30.A)

Test Point N° 1 Condition Use Fuse and relay box - Testing Main Power Relay Control (A.30.A) to check MAIN POWER RELAY. 2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 3 and connector X-316 pin A. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 3 and connector X-C23 pin 21. 4 Condition Disconnect connector X-316 from the IGNITION BACKFEED DIODE V-007 Check Use ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A) to test the diode 5 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 2 and connector X-C23 pins 9 and 11. 6 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 1 and connector X-C23 pin 3. 7 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-9 pin 6 and connector X-15 pin 1. 8 Condition Disconnect connector X-15 from the ACCESSORY BACKFEED DIODE V-004 Check Use ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A) to test the diode

Expected Result Result Test satisfactory. Action Go to test 2

Other Result (Possible Cause) Action If problems are found, repair them. This test is complete.

Result No wire problems Action Go to test 3

Action If wire problems are found, repair or replace broken wire 132/ 133 (Orange).

Result No wire problems Action Go to test 4

Action If wire problems are found, repair or replace broken wire 132 (Orange) / 131 (White).

Result Test satisfactory Action Go to test 5

Result Diode is faulty, Action replace the diode.

Result No wire problems Action Go to test 6

Action If wire problems are found, repair or replace broken wire 624/ 622 (White) or 624/623 (White).

Result No wire problems Action Go to test 7

Action If wire problems are found, repair or replace broken wire 140 (Red) / 311 (Yellow).

Result No wire problems Action Go to test 8

Action If wire problems are found, repair or replace broken wire 138 (Orange) / 153 (Black).

Result Test satisfactory Action Go to test 9

Result Diode is faulty, Action replace the diode.

84522361 15/06/2011

B.80.A / 4

ENGINE AND PTO IN - STARTING SYSTEM

Test Point N° 9 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-15 pin 2 and connector X-C23 pin 22. 10 Condition Use Data bus - General specification Instrument Cluster pin information (A.50.A) to check Instrument Cluster pins 3, 9 ,11, 21, and 22.

Expected Result Result No wire problems Action Go to test 10

Other Result (Possible Cause) Action If wire problems are found, repair or replace broken wire 137 (White).

Action Result If resistance problems are found, No resistance problems replace the Instrument Cluster. Action The Ignition Switch S-008 has failed. Replace the IGNITION SWITCH S-008.

84522361 15/06/2011

B.80.A / 5

Index ENGINE AND PTO IN - B STARTING SYSTEM - 80.A Cold start aid - Overview Engine preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Start control - Testing Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84522361 15/06/2011

B.80.A / 6

84522361 15/06/2011

B.80.A / 7

New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

84522361 15/06/2011 EN

SERVICE MANUAL TRANSMISSION, DRIVE AND PTO OUT

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

C

Contents TRANSMISSION, DRIVE AND PTO OUT - C

TRANSMISSION Hydrostatic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.F C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

C

TRANSMISSION, DRIVE AND PTO OUT - C TRANSMISSION Hydrostatic - 20.F

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

C.20.F / 1

Contents TRANSMISSION, DRIVE AND PTO OUT - C TRANSMISSION Hydrostatic - 20.F

TECHNICAL DATA Pump General specification 35cc EH Hydrostatic pump, used with small and medium frame models. . . . . . . . 5 L213, L215, L218, L220

- General specification 46cc EH Hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L223, L225, L230, C227, C232, C238

General specification 46cc EHF Hydrostatic pump, used with large frame models. . . . . . . . . . . . . . . . . . . 7 L230, C238

General specification Mechanical controls 35cc Hydrostatic tandem pump, used with small and medium frame models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 L213, L215, L218, L220

General specification 46cc Hydrostatic tandem pump, used with medium and large frame models. . . . . 9 General specification 53cc hydrostatic pump, used with large frame models. . . . . . . . . . . . . . . . . . . . . . . 10 General specification 46cc Hydrostatic tandem pump, used with large frame models. . . . . . . . . . . . . . . 11

Motor General specification for EH and Mechanical 325cc single speed motor on medium and small frame models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 L213, L215, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

General specification for mechanical 470cc single speed motor on medium and large frames . . . . . . . 13 L223, L225, L230

General specification for 325cc 2 speed motor on medium frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L218, L220

General specification for EH and Mechanical 470cc 2 speed motor on medium and large frames . . . . 15 L223, L225, L230

General specification for track drive 2 speed motor on medium and large frames . . . . . . . . . . . . . . . . . . 16 C232, C238

FUNCTIONAL DATA Pump Overview Hydrostatic pump model identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SERVICE TRANSMISSION Hydrostatic Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Command Remove Right hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls 84522361 15/06/2011

C.20.F / 2

Install Right hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Remove Left hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Install Left hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Relief valve Pressure test Ground Drive Relief Valve - Manual control models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L213, L215, L218, L220, L223, L225, L230

Pressure test (Machines Equipped with EH Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 L218, L220, L223, L225, L230, C227, C232, C238

Pump Travel adjust (Stopping machine creep) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 L220

Adjust Servo Piston Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 L220

Adjust Hydraulic Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 L220

Remove mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Install mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Remove EH hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Install EH hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Adjust Mechanical pump creep setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 L213, L215, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 L213, L215, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls, C227 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

Remove track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Install track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Sensing system Remove Right hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

C.20.F / 3

Install Right hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Remove Left hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Install Left hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

DIAGNOSTIC TRANSMISSION Hydrostatic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

84522361 15/06/2011

C.20.F / 4

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - General specification 35cc EH Hydrostatic pump, used with small and medium frame models. L213, L215, L218, L220

Manufacturer

Bosch Rexroth

Type

Tandem, Axial Piston, EH control

Direction of Rotation

Clockwise

Nominal displacement

35 cm³ (2.1 in³)

Shaft test speed

2000 RPM

Charge pressure

25 bar (363 psi)+/- 1.0 bar (15 psi)

Differential pressure A

360 bar (5220.0 psi)+/- 10 bar (145.0 psi)

Differential pressure B

360 bar (5220.0 psi)+/- 10 bar (145.0 psi)

Nominal voltage

14 V

Port

(A) Service line port (B) Service line port (T) Case drain port (X1) Control Pressure (before the orfice) (X2) Control Pressure (before the orfice) (R) Air bleed (Ma) Pressure gauge operating pressure A (Mb) Pressure Gauge Operating pressure B (G) Pressure port for auxiliary circuit (G2) Pressure port for auxiliary circuit (S) Boost suction port (Mg) Pressure gauge operating pressure G (Yst) Control pressure gauge port

84522361 15/06/2011

C.20.F / 5

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - General specification 46cc EH Hydrostatic pump L223, L225, L230, C227, C232, C238

Manufacturer Type Direction of Rotation Nominal displacement Shaft test speed Charge pressure Differential pressure A Differential pressure B Nominal voltage Port

Bosch-Rexroth Tandem pump Clockwise 46 cm³ (3 in³) 2000 RPM 25 bar (363 psi +/- ) 1 bar (15 psi) 360 bar (5220.0 psi +/- 14.5 bar +/- 1) 360 bar (5220.0 psi +/- 14.5 bar +/- 1) 14 V (A) Service line port (B) Service line port (T) Case drain port (X1) Control Pressure (before the orfice) (X2) Control Pressure (before the orfice) (R) Air bleed (Ma) Pressure gauge operating pressure A (Mb) Pressure Gauge Operating pressure B (G) Pressure port for auxiliary circuit (G2) Pressure port for auxiliary circuit (S) Boost suction port (Mg) Pressure gauge operating pressure G (Yst) Control pressure supply port

84522361 15/06/2011

C.20.F / 6

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - General specification 46cc EHF Hydrostatic pump, used with large frame models. L230, C238

Manufacturer

Bosch Rexroth

Type

Combination pump

Direction of Rotation

Clockwise

Nominal displacement

46 cm³ (3 in³)

Maximum displacement port A

46 cm³ (3 in³ +/- ) 0.9 cm³ (0.1 in³)

Maximum displacement port B

46 cm³ (3 in³ +/- ) 0.9 cm³ (0.1 in³)

Shaft test speed

2000 RPM

Charge pressure

25 bar (363 psi +/- ) 1 bar (15 psi)

Relief valve A

385 bar (5583 psi +/- ) 10 bar (145 psi)

Differential pressure A

360 cm³ (22 in³ +/- ) 10 cm³ (0.6 in³)

Relief valve B

385 bar (5583 psi +/- ) 10 bar (145 psi)

Differential pressure B

360 cm³ (22 in³ +/- ) 10 cm³ (0.6 in³)

Nominal voltage

12 V

Port

(A) Service line port (B) Service line port (T) Case drain port (X1) Control Pressure (before the orfice) (X2) Control Pressure (before the orfice) (R) Air bleed (Ma) Pressure gauge operating pressure A (Mb) Pressure Gauge Operating pressure B (G) Pressure port for auxiliary circuit (G2) Pressure port for auxiliary circuit (S) Boost suction port (Mg) Pressure gauge operating pressure G (Yst) Control pressure gauge port

84522361 15/06/2011

C.20.F / 7

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - General specification Mechanical controls 35cc Hydrostatic tandem pump, used with small and medium frame models. L213, L215, L218, L220

Manufacturer

Sauer-Danfoss

Type

Pump-Tandem - Axial piston

Direction of Rotation

Clockwise - When viewed looking into the input shaft

Front and rear displacments

35 cm³ (2.1 in³)

Manual swashplate displacement control

19.05 mm (0.75 in) square input shaft

Charge pressure relief setting

24 - 25 bar (348 - 363 psi) @ 1800 RPM

System pressure relief setting

345 bar (5003 psi) +5 / 0 %

84522361 15/06/2011

C.20.F / 8

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - General specification 46cc Hydrostatic tandem pump, used with medium and large frame models. Manufacturer

Bosch-Rexroth

Type

Combination pump

Direction of Rotation

Clockwise

Nominal displacement

46 cm³ (2.8 in³)

Maximum displacement port A

46 cm³ (2.8 in³ +/- ) 0.9 cm³ (0.1 in³)

Maximum displacement port B

46 cm³ (2.8 in³ +/- ) 0.9 cm³ (0.1 in³)

Shaft test speed

2000 RPM

Charge pressure

25 bar (363 psi +/- ) 1.0 bar (15 psi)

Relief valve A

385 bar (5583 psi +/- ) 10 bar (145 psi)

Differential pressure A

360 cm³ (22 in³ +/- ) 10 cm³ (0.6 in³)

Relief valve B

385 bar (5582 psi +/- ) 10 bar (145 psi)

Differential pressure B

360 cm³ (22 in³ +/- ) 10 cm³ (0.6 in³)

Nominal voltage

12 V

Port

(A) Service line port (B) Service line port (T) Case drain port (X1) Control Pressure (before the orfice) (X2) Control Pressure (before the orfice) (R) Air bleed (Ma) Pressure gauge operating pressure A (Mb) Pressure Gauge Operating pressure B (G) Pressure port for auxiliary circuit (G2) Pressure port for auxiliary circuit (S) Boost suction port (Mg) Pressure gauge operating pressure G (Yst) Control pressure gauge port

84522361 15/06/2011

C.20.F / 9

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - General specification 53cc hydrostatic pump, used with large frame models. Manufacturer

Rexroth

Type

Piston pump

Direction of Rotation

Clockwise

Nominal displacement

63 cm³ (3.8 in³)

Test speed

2800 RPM

Charge pressure

25 bar (363 psi)

Relief valve A

276 bar (4002 psi)

Differential pressure A

241 bar (3495 psi)

Relief valve B

207 bar (3002 psi)

Differential pressure B

182 bar (2639 psi)

Nominal voltage

12 V

84522361 15/06/2011

C.20.F / 10

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - General specification 46cc Hydrostatic tandem pump, used with large frame models. Manufacturer

Sauer-Danfoss

Type

Pump-Tandem

Direction of Rotation

Clockwise

Front and rear displacments

46 cm³ (2.8 in³)

Bushed block rotating speed

up to 3600 RPM

Manual displacement control

Mechanical input, servo actuated with swashplate position feedback

Charge pump flow

30.3 l/min (8 US gpm) at 1800 RPMwith 48.9 °C (120 °F) oil

Charge pressure relief setting

24 - 25 bar (348 - 363 psi) @ 1800 RPM with 48.9 °C (120 °F) oil

System pressure relief setting

360 bar (5220 psi) +5 % set at 4.5 - 4.9 l/min (1.2 - 1.3 US gpm) with 48.9 °C (120 °F) oil

84522361 15/06/2011

C.20.F / 11

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Motor - General specification for EH and Mechanical 325cc single speed motor on medium and small frame models L213, L215, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

Manufacturer

Bosch-Rexroth

Type

Direct drive radial piston motor

Direction of Rotation

Bi-directional

Displacement

325 cm³/rev (20 in³/rev)

Speed

Maximum Operating: 330 RPM

Maximum Operating Pressure

System operating differential relief pressure 345 bar (5003 psi).

Brake Release

11 - 15 bar (160 - 218 psi)

Ports

Main Ports: A and B Case Drain Port: L Brake Release Port: Z

84522361 15/06/2011

C.20.F / 12

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Motor - General specification for mechanical 470cc single speed motor on medium and large frames L223, L225, L230

Manufacturer

Bosch-Rexroth

Type

Direct drive radial piston motor

Direction of Rotation

Bi-directional

Displacement

470 cm³/rev (28.7 in³/rev)

Speed

Maximum Operating: 385 RPM

System Operating Pressure

Differential relief pressure 345 bar (5003 psi).

Brake Release

11 - 15 bar (160 - 218 psi)

Ports

Main Ports: A and B Case Drain Port: L Brake Release Port: Z

84522361 15/06/2011

C.20.F / 13

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Motor - General specification for 325cc 2 speed motor on medium frames L218, L220

Manufacturer

Bosch-Rexroth

Type

Direct drive radial piston motor

Direction of Rotation

Bi-directional

Displacement

325 - 200 cm³/rev (19.8 - 12.2 in³/rev).

Speed

Maximum Operating: 330 RPM, 430 RPM at minimum displacement.

Output Shaft

10 Tooth RC 80 Sprocket

Maximum Operating Pressure

System operating differential relief pressure 345 bar (5003 psi).

Brake Release

11 - 15 bar (160 - 218 psi)

Displacement Shift Pressure

15 bar (218 psi) maximum.

Ports

Main Ports: A and B Case Drain Port: L Brake Release Port: Z

84522361 15/06/2011

C.20.F / 14

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Motor - General specification for EH and Mechanical 470cc 2 speed motor on medium and large frames L223, L225, L230

Manufacturer

Bosch-Rexroth

Type

Direct drive radial piston motor

Direction of Rotation

Bi-directional

Displacement

470 - 282 cm³/rev (28.7 - 17.2 in³/rev).

Speed

Maximum Operating: 385 RPM, 465 RPM at minimum displacement.

Output Shaft

9 Tooth RC 100 Sprocket

Maximum Operating Pressure

414 bar (6000 psi) System operating differential relief pressure 345 bar (5003 psi).

Brake Release

11 - 15 bar (160 - 218 psi)

Displacement Shift Pressure

15 bar (218 psi) maximum.

Ports

Main Ports: A and B Case Drain Port: L Brake Release Port: Z

84522361 15/06/2011

C.20.F / 15

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Motor - General specification for track drive 2 speed motor on medium and large frames C232, C238

Manufacturer Type Direction of Rotation Displacement Speed Maximum Operating Pressure Brake Release Displacement Shift Pressure Ports

Bonfiglioli Radial or Axial piston with planetary reducer Dual rotation Two speed 50.9 - 33.1 cm³/rev (3.1 - 2.0 in³/rev) with 21.58:1 output reducer. Maximum Operating: 106 RPM in low range. 162 RPM in high range. 241 bar (3500 psi) Maximum differential relief pressure 345 bar (5003 psi). Fully released at 13 bar (189 psi). Maximum allowable brake pressure 49 bar (711 psi) 15 bar (218 psi) maximum. Service Ports: P1 and P2 2 Speed Control Port: Ps Drain Port: Dr

84522361 15/06/2011

C.20.F / 16

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - Overview Hydrostatic pump model identification The skid steer product line is very versatile and comes with many options. The information below is to help with understanding what hydrostatic pumps may be equipped with certain models. Model

Controls

L213

Mechanical

L215

Mechanical

L218

Mechanical Electro-hydraulic

L220

Mechanical Electro-hydraulic

L223

Mechanical Electro-hydraulic

L225

Mechanical Electro-hydraulic

L230

Mechanical

Electro-hydraulic

C227

Electro-hydraulic

C232

Electro-hydraulic

C238

Electro-hydraulic

84522361 15/06/2011

C.20.F / 17

Hydrostatic Pump Sauer Danfoss 35 cm³ mechanical hydrostatic tandem pump Sauer Danfoss 35 cm³ mechanical hydrostatic tandem pump Sauer Danfoss 35 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 35 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Sauer Danfoss 46 cm³ mechanical hydrostatic tandem pump containing bushed blocks for use with 67 kW (91.1 Hp) F5C engines Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Optional: Bosch Rexroth 46 cm³ electro-hydraulic EHF hydrostatic pump Bosch Rexroth 53 cm³ electro-hydraulic EHF hydrostatic pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Bosch Rexroth 46 cm³ electro-hydraulic hydrostatic pump Optional: Bosch Rexroth 46 cm³ electro-hydraulic EHF hydrostatic pump Bosch Rexroth 53 cm³ electro-hydraulic EHF hydrostatic pump

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

TRANSMISSION Hydrostatic - Cleaning The hydrostatic system is a closed loop made up of the charging pump, piston pump, drive motors and the hoses between these components. The hydraulic cooler and reservoir are also part of the closed loop system. Any contamination in the hydrostatic system will stay in the closed loop, and probably cause damage. If the piston pump or a motor in the hydrostatic system is removed for repair or replacement, you must clean the hydrostatic system. If any contamination is left in the closed loop, the contamination will damage the remaining components of the hydrostatic system. 1.

Remove the piston pumps and at least the motor in the circuit that failed. If there is a quantity of contamination present, removal of the opposite pump and motor is also required.

2.

Disassemble, clean, and inspect the piston pumps and motor(s).

3.

Clean all hoses and tubes in the hydrostatic system. Remove each hose and tube from the machine. Flush and clean the hoses and tubes with hot soapy water. Hang and allow them to air dry. Hoses and tubes must be dry before installing.

4.

Install, inspected and repaired, or new piston pumps and motors.

5.

Change the hydraulic filter.

6.

Make sure that the hydraulic system is clean so that the charge pump will not cause new contamination in the closed loop. Remember that the oil cooler may have internal passages that can trap and hold contamination that can be dislodged later and cause a repeat failure.

NOTE: THE FOLLOWING PROCEDURE SHOULD BE USED FOR CLEANING HOSES, TUBES, AND FITTINGS. It is recommended that hoses, tubes and fittings be cleaned with a steam cleaner and dried with compressed air. 7.

Fasten the parts to a rack in a position as near to vertical as possible. This will allow water to drain as you flush parts.

8.

Clean the exterior surfaces of the parts thoroughly.

9.

Clean the interior surfaces of the parts. Use hot water and soap first. Then use clean hot water to rinse.

NOTE: If the steam cleaner does not have a soap injection system, spray an oil solvent into the parts. This will dissolve the oil film that holds contaminants inside the parts. Then use clean hot water to rinse. 10.

Fasten the parts in the rack so that the parts can be flushed from opposite ends. Repeat steps 8 an 9.

11.

Use compressed air to dry the inside of each part. Dry the parts from both ends to make sure all of the water is removed.

12.

Install caps or plugs in the ends of each hose, tube or fitting as soon as the parts are dry. This will prevent entry of contaminants. Remove the caps or plugs from the part only when the part is in position in the machine and you are ready to make the connection.

84522361 15/06/2011

C.20.F / 18

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Command - Remove Right hand drive solenoid(s) L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) NOTE: This procedure covers how to remove the right hand forward and right hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1.

2.

3.

4.

Locate the electro-hydraulic hydrostatic pump (1).

931001814

1

931001814

2

931001814

3

Locate the drive solenoid that needs to be removed. The right hand reverse (1) and right hand forward (2) solenoids are located on the input shaft side of the hydrostatic pump.

Disconnect the connector (1) from the solenoid. Unscrew the cap (2).

Slide the solenoid off.

84522361 15/06/2011

C.20.F / 19

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Command - Install Right hand drive solenoid(s) L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

NOTE: This procedure covers how to install the right hand forward and right hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1.

2.

Place the solenoid on to the valve body. See picture for location of solenoids. The right hand reverse (1) and right hand forward (2) solenoids are located on the input shaft side of hydrostatic pump.

931001814

1

931001814

2

Screw the cap (2) onto valve body. Connect the connector (1) to the solenoid.

84522361 15/06/2011

C.20.F / 20

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Command - Remove Left hand drive solenoid(s) L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) NOTE: This procedure covers how to remove the left hand forward and left hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1.

2.

3.

4.

Locate the electro-hydraulic hydrostatic pump (1).

931001814

1

931001814

2

931001814

3

Locate the drive solenoid that needs to be removed. The left hand forward (1) and left hand reverse (2) solenoids are located near the auxiliary pump.

Disconnect the connector (1) from the solenoid. Unscrew the cap (2).

Slide the solenoid off.

84522361 15/06/2011

C.20.F / 21

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Command - Install Left hand drive solenoid(s) L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

NOTE: This procedure covers how to install the left hand forward and left hand reverse drive solenoids located on the electro-hydraulic hydrostatic pump. 1.

2.

Place the solenoid on to the valve body. See picture for location of solenoids. The left hand reverse (1) and left hand forward (2) solenoids are located near the auxiliary pump.

931001814

1

931001814

2

Screw the cap (2) onto valve body. Connect the connector (1) to the solenoid.

84522361 15/06/2011

C.20.F / 22

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Relief valve - Pressure test Ground Drive Relief Valve - Manual control models L213, L215, L218, L220, L223, L225, L230

Test Procedure: 1.

Raise and securely block the unit off the ground.

2.

Remove the brake release line from the tee fitting that connects to the B port (1) of the brake valve (2).

3.

4.

931002074

1

931002074

2

Cap the tee fitting that connects to the B port (1) of the brake valve (2).

Connect a 690 bar (10,000 psi) pressure gauge to the high pressure loop gauge port. See the illustration below.

HI01E019

3

Sauer M46 (1) Right Hand motor reverse test port, (2) Right Hand forward test port, (3) Left Hand motor test port, (4) Left Hand reverse test port

84522361 15/06/2011

C.20.F / 23

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

93111529

4

Sauer M35 right side view (1) front service line port, (2) rear service line port

93111523

5

Sauer M35 top view (1) front service line port, (2) rear service line port (opposite side bottom) 5.

Lower the cab and route the pressure gauge so that it can be viewed while running the unit from the operator’s seat. Start the unit and disengage interlocks to operate unit.

NOTE: An error will appear on the Instrument Cluster during this test. When the unit is shut down and all connections are returned to normal, the fault code will be stored as inactive. This fault can be cleared using the Electronic Service Tool (EST). 6.

If the hydraulic oil is not at operating temperature, run the engine at full throttle and hold the bucket control lever in the ROLLBACK position for 5 seconds. Then return the bucket control lever to NEUTRAL for 5 seconds. Repeat this cycle until the temperature of the oil is at least 52°C (125°F).

7.

Increase the engine speed to full throttle. Move the control lever for the circuit being tested one half the distance of full travel and watch the pressure gauge. When the pressure gauge stops increasing, read the pressure gauge and move the control lever to NEUTRAL.

8.

The correct pressure is the gauge reading minus the charge pressure. If the pressure is not correct, use a new circuit relief valve. You can temporarily repair a forward circuit by interchanging a functioning reverse circuit relief valve with the forward circuit relief valve. See the illustration below.

84522361 15/06/2011

C.20.F / 24

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

HI01E019_2

6

Sauer M46

93111523

7

Sauer M35 top view (1) bypass relief valves, (2) bypass relief valves (opposite side bottom)

93111529

8

Sauer M35 right side view (1) charge pressure relief valve 9.

Reconnect the brake lines to their original state.

84522361 15/06/2011

C.20.F / 25

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Relief valve - Pressure test (Machines Equipped with EH Controls) L218, L220, L223, L225, L230, C227, C232, C238

1.

Connect a 68 947 kPa (690 bar) (10,000 psi) pressure gauges to the test ports MA (1) and MB (2). See the figure below.

NOTICE: For the following test the machine MUST be raised up on supports until the tires are above the floor. This is a safety procedure if the parking brakes fail to hold. NOTE: You will need two people to perform this test. The operator seat must be in the raised position to gain access to the hydrostatic pump. This test can be done in either ISO or H pattern. H pattern in preferred, only one pump will be actuated at a time.

2.

Connect a 4137 kPa (41.4 bar) gauge in the Yst port located on the top center of pump.

3.

Remove brake release lines from B port of the brake valve, plug lines and cap fittings in B port.

4.

If the hydraulic oil is not at operating temperature run the engine at full throttle and hold the bucket control lever in the ROLLBACK position for 30 seconds. Then return the bucket control lever to NEUTRAL for 15 seconds. Repeat this cycle until the temperature of the oil is at least 52°C (125°F).

5.

Run the engine at low idle. Move the ground drive control lever slowly to the FORWARD position.

6.

Increase the engine speed to full throttle. Slowly move the ground drive control lever for the circuit being tested one half the distance of full travel and watch the pressure gauge. When the pressure gauge stops increasing, read the pressure gauge and move the ground drive control lever to NEUTRAL.

7.

The correct pressure is the gauge reading minus the charge pressure. If the pressure is not correct, use a new circuit relief valve. You can temporarily repair a forward circuit by interchanging a functioning reverse circuit relief valve with the forward circuit relief valve. See the figure below.

(1)Right Hand Forward Drive Circuit Relief Valve (2) Right Hand Reverse Drive Circuit Relief Valve

(3) Left Hand Forward Drive Circuit Relief Valve (4) Left Hand Reverse Drive Circuit Relief Valve

84522361 15/06/2011

C.20.F / 26

20111250

1

20111248

2

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - Travel adjust (Stopping machine creep) L220

Pump Adjustments Stopping Machine Creep 1.

In order to correct a creeping hydrostatic drive, a systematic diagnosis procedure must be followed. First, determine if it is the pump’s fault by disconnecting the control linkage to the servo control levers on the pump. If the problem disappears, inspect the linkage and correct the problem. Improper rod length, binding control bushings, binding control cables, etc., are some common problems. If, after disconnecting the linkage, the system still moves, pump adjustments are available to correct the problem. If the only operational symptom noted is that one or both drive systems continue to move with the controls in neutral, adjustment of the servo control valve may possibly be all that is required (See Pump - Adjust Hydraulic Neutral (C.20.F)). If the unit does not track in a straight line or if one side tends to continue in the direction that it was going last, it is recommended to adjust the servo piston centering mechanism before adjusting the hydraulic neutral control.

Centering the Servo Piston 2.

The servo control piston has a very strong spring centering mechanism to return the pump to neutral condition when the hydraulic servo control is in neutral. A control rod from the centering mechanism runs through one end cover to allow for external adjustment. Use the following procedure to center the pilot servo piston:

NOTE: You will need two people to perform this procedure. NOTICE: The machine MUST be raised up on supports until the tires are above the floor. This is a safety procedure if the parking brakes fail to hold. 3.

Raise and secure block the unit off the ground.

4.

Disconnect and cap the charge pressure supply line (from the brake release solenoid valve) to the servo control inlet line. This is a small steel line that runs in between the two servos. This will allow you to adjust both pumps without hydraulic interference to the mechanical adjust you are performing.

931001966

5.

Start the engine and run at full throttle.

84522361 15/06/2011

C.20.F / 27

1

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

6.

Loosen the jam nut and turn the servo adjusting screw in one direction until the tires just begin rotate, note the position of the adjusting screw. Turn the adjusting screw in the opposite direction until the tires just begin to rotate in the opposite direction, note the position of the screw. Repeat these steps again to verify the position of the screw when the tires begin to rotate. Center the adjusting screw between both positions and tighten the lock nut. NOTE: if more than one full turn of the adjusting screw is required to attain tire rotation in each direction, the internal locking nut at the servo piston centering spring is probably misadjusted (see servo centering spring adjustment).

NOTE: If more than one full turn of the adjusting screw is required to attain tire rotation in each direction, the internal locking nut at the servo piston centering spring is probably misadjusted. Perform Pump - Adjust Servo Piston Centering Spring (C.20.F). 7.

If the other pump requires adjustment, repeat Step 6 on the other pump.

8.

Stop the engine.

9.

Uncap and reconnect the charge pressure supply line

84522361 15/06/2011

C.20.F / 28

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - Adjust Servo Piston Centering Spring L220

NOTE: If more than one full turn of the servo adjusting screw was required when performing Pump - Travel adjust (C.20.F), or if the machine has the tendency to continue traveling in the direction that it was going last, both forward and reverse, check and adjust the locking nut on the adjusting screw at the servo piston centering spring. The only way for this nut to change adjustment, is if the internal centering spring should break, the spring retainer snap ring fails or the lock nut becomes loose. 1.

Remove the cap and external sealing nut (1).

2.

Remove the bolts retaining the servo piston cover in place.

3.

Rotate the piston cover off of the servo adjusting screw.

4.

Tighten or loosen the centering spring lock nut (2) until all looseness is removed from the centering spring. To adjust the lock nut, hold the screw with an Allen Wrench and use whatever is necessary to adjust the nut inside the piston bore. If the lock nut is too tight or too loose, the centering spring will not function correctly. The lock nut must be exactly positioned just tight to the spring. After the lock nut is adjusted it must remain in that exact position, the nut may have to be replaced to provide adequate holding power.

5.

Install the piston end covers and bolts.

6.

Perform Pump - Travel adjust (Stopping machine creep) (C.20.F) to center the servo piston.

84522361 15/06/2011

C.20.F / 29

23111053

1

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - Adjust Hydraulic Neutral L220

1.

Raise and secure block the unit off the ground.

2.

Start and run the engine at full throttle.

3.

Loosen the lock bolt for the servo control adjustment bracket. Move the bracket in one direction until the tires just begin to rotate in one direction and mark the position of the bracket. Move the bracket in the opposite direction until the tires just begin to rotate in opposite direction and mark the position of the bracket. Repeat the above steps to assure that the proper bracket position was marked. Center the adjustment bracket between the marks and tighten the lock bolt. Securely hold the bracket in position when tightening the lock bolt to prevent movement caused by the bolt head.

4.

After the bracket has been secured in position, gradually move the pump control lever away from the centered position in both directions. The servo control adjustment bracket is properly adjusted when an even amount of lever travel is required to begin tire rotation in both directions. Readjust as necessary to attain the centered position.

5.

If the other pump requires adjustment, repeat Steps 3 and 4 on the other pump.

6.

Stop the engine.

84522361 15/06/2011

C.20.F / 30

23111054

1

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - Remove mechanical hydrostatic pump L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Prior operation: Tilt system - Tilt (E.34.A) 1.

2.

3.

Label and disconnect the four left hand side hydraulic hoses (1) and cap open ports

931002072

1

931002073

2

931002074

3

Label and disconnect the gear pump hydraulic tube (1) and supply hose (2) and cap open ports.

Label and disconnect right hand side hydraulic hoses (1) and cap open ports

84522361 15/06/2011

C.20.F / 31

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

4.

5.

6.

7.

Disconnect control linkage hardware (1).

931002075

4

931002076

5

931002077

6

931002078

7

Disconnect electrical connection (1).

Using a metal rod as a brace across the pump attach lifting straps and hoist to support pump, as shown.

Remove the four pump mounting bolts (1) and (2).

84522361 15/06/2011

C.20.F / 32

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

8.

Using the hoist carefully remove pumps.

931002079

Next operation: Pump - Install mechanical hydrostatic pump (C.20.F)

84522361 15/06/2011

C.20.F / 33

8

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - Install mechanical hydrostatic pump L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Prior operation: Pump - Remove mechanical hydrostatic pump (C.20.F) 1.

Before pump installation, apply MOLYKOTE® G-N METAL ASSEMBLY PASTE or NEW HOLLAND AMBRA GR75MD to the pump and the coupling splines. Pre-fill the pump with clean hydraulic oil. Inspect O-ring on the pump pilot and replace if necessary. Lubricate the O-ring with clean hydraulic oil.

2.

Position the pump in the mounting location. Rotate the gear pump shaft until it aligns with the coupling splines at the rear of the hydrostatic pump. After the splines are aligned, move the pump inward until the mounting flange is flush with the mounting surface of the hydrostatic pump.

3.

931002077

1

931002078

2

Apply LOCTITE® 243 to the pump mounting bolts (1). Install washers on the bolts and install the bolts (1) into the pump mounting flange. Tighten the mounting bolts to 86 - 117 N·m (63.4 - 86.3 lb ft). Apply LOCTITE® 243 to pump support bracket bolts (2). Install washer on bolts and install bolts. Tighten the pump support bracket bolts 55 - 60 N·m (40.6 - 44.3 lb ft).

84522361 15/06/2011

C.20.F / 34

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

4.

5.

6.

7.

Connect electrical connection (1).

931002076

3

931002075

4

931002074

5

931002073

6

Connect control linkage (1).

Connect the right hand side hydraulic hoses (1).

Connect the rear hydraulic tube (1) and supply hose (2).

84522361 15/06/2011

C.20.F / 35

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

8.

Connect the four left hand side hydraulic hoses (1) to the correct ports.

931002072

84522361 15/06/2011

C.20.F / 36

7

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - Remove EH hydrostatic pump L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Prior operation: Tilt system - Tilt (E.34.A) Oil cooler - Remove (A.10.A) 1.

2.

3.

Label and disconnect control wires (1) on bottom of pumps

931001961

1

20111248

2

931001963

3

Label and disconnect the two front (1) and two rear (2) pump control connections.

Label and disconnect the hydraulic oil temperature sender (1).

84522361 15/06/2011

C.20.F / 37

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

4.

5.

6.

7.

Label and disconnect the right hand side hydraulic hose (1).

931001964

4

931001965

5

931001966

6

931001970

7

Label and disconnect the oil supply hose (1) by loosening the hose clamp and cap ports.

Label and disconnect the top hydraulic tube (1) and cap open ports.

Label and disconnect right hand side drive motor hoses (1) and cap open ports.

84522361 15/06/2011

C.20.F / 38

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

8.

9.

10.

11.

Label and disconnect left hand side drive motor hoses (1) and cap open ports.

931001971

8

931001972

9

Label and disconnect hydraulic hose (1) and cap open ports.

Label and disconnect case drain hose (1) and cap open ports.

931001963

10

931001955

11

Label and disconnect gear pump supply hose (1) and cap open ports.

84522361 15/06/2011

C.20.F / 39

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

12.

13.

Label and disconnect gear pump hydraulic tubes (1) and cap open ports.

931001956

12

931001974

13

931001928

14

931001976

15

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Place a lifting strap around the pump and using a hoist support the pump, as shown. 14.

15.

Remove the two mounting bolts and washers (1) from the pump.

Using the hoist, carefully remove pumps.

Next operation: Pump - Install EH hydrostatic pump (C.20.F)

84522361 15/06/2011

C.20.F / 40

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - Install EH hydrostatic pump L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Prior operation: Pump - Remove EH hydrostatic pump (C.20.F) NOTE: Before pump installation, apply NEW HOLLAND AMBRA GR75MD to the pump and the coupling splines. Mount coupling star (1) to pump shaft with supplier logo facing out, toward the engine. Set coupling to dimension shown in the image below. Torque set screws to 25.7 - 28.3 N·m (19.0 - 20.9 lb ft) . Pre-fill the pump with clean hydraulic oil. Inspect O-ring on the pump pilot and replace if necessary. Lubricate the O-ring with clean hydraulic oil. 1.

2.

3.

Position the pump in the mounting location. Rotate the gear pump shaft until it aligns with the coupling splines (1) at the rear of the hydrostatic pump. The distance (X) should be 49 mm (1.9 in) . After the splines are aligned, move the pump inward until the mounting flange is flush with the mounting surface of the hydrostatic pump.

93111555A

1

931001928

2

931001956

3

Apply LOCTITE® 243 to the pump mounting bolts (1). Install washers on the bolts and install the bolts into the pump mounting flange. Tighten the mounting bolts to 86 - 117 N·m (63.4 - 86.3 lb ft).

Connect gear pump hydraulic hoses (1) as shown.

84522361 15/06/2011

C.20.F / 41

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

4.

5.

6.

7.

Connect the gear pump supply hose (1) and tighten hose clamp.

931001955

4

931001963

5

931001972

6

931001971

7

Connect case drain hose (1) and secure with clamp.

Connect hydraulic hose (1), as shown.

Connect left hand side drive motor hoses (1).

84522361 15/06/2011

C.20.F / 42

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

8.

9.

10.

11.

Connect right hand side motor hoses (1).

931001970

8

931001966

9

Connect the top hydraulic hose (1).

Connect the oil supply hose (1) and tighten hose clamp.

931001965

10

931001964

11

Connect right hand side hydraulic hose (1).

84522361 15/06/2011

C.20.F / 43

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

12.

13.

14.

Connect hydraulic oil temperature sender (1) and secure with nut.

931001963

12

20111248

13

931001961

14

Connect the front (1) and rear pump control connections (2).

Connect the sensor wires (1) located on the bottom of pumps.

84522361 15/06/2011

C.20.F / 44

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Pump - Adjust Mechanical pump creep setting 1.

2.

3.

Raise and support (1) the machine.

931002069

1

931002075

2

931002075

3

Loosen the jam nut (1) on the adjustment rod.

Rotate the rod (1) until the tires rotate in a forward direction.

4.

Turn the rod in opposite direction until the tires just rotate in a reverse direction. Count the number of turns for the rod to go from the tires rotating forward to the tires rotating in reverse.

5.

Turn the rod in the opposite direction ½ the number of turns recorded in step number 4 of this procedure. This should be the center of neutral.

84522361 15/06/2011

C.20.F / 45

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

6.

7.

Loosen the jam nut (1) on the adjustment rod (opposite side).

931002075

4

931002075

5

Rotate the rod (1) until the tires rotate in a forward direction.

8.

Turn the rod in opposite direction until the tires just rotate in a reverse direction. Count the number of turns for the rod to go from the tires rotating forward to the tires rotating in reverse.

9.

Turn the rod in the opposite direction ½ the number of turns recorded in step number 8 of this procedure. This should be the center of neutral.

84522361 15/06/2011

C.20.F / 46

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Motor - Remove L213, L215, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Prior operation: Tilt system - Tilt (E.34.A). 1.

2.

3.

The loader must be raised and supported with the tires off the ground. Used adequate blocks or jack stands to safely support the loader.

931002069

1

931002070

2

931002081

3

Remove the wheel hardware (1) and pull wheels from hub.

Place suitable container under chain tank drain plug and remove drain plug (3) and drain chain oil.

84522361 15/06/2011

C.20.F / 47

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

4.

5.

6.

Remove the six bolts (2) securing the drive chain inspection cover and remove cover.

931002080

4

931002082B

5

931002083B

6

Remove front and rear axle housing hardware (4).

Remove front and rear axle housings

84522361 15/06/2011

C.20.F / 48

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

7.

8.

9.

Push the sprocket forward and remove chains from drive sprocket, as shown.

931002084

7

931002085B

8

931002086

9

Label and disconnect hydraulic hoses (1) from hydrostatic drive motor and cap the open hoses and ports.

Disconnect shift tube (on 2 speed equipped models).

84522361 15/06/2011

C.20.F / 49

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

10.

Remove and discard hydraulic motor mounting hardware (2).

NOTE: DO NOT reuse motor mounting hardware after tightening to spec. Hardware is permanently stretched during tightening and must be discarded if loosened.

11.

931002085B

10

931002087

11

Use acceptable lifting equipment and remove the drive motor/brake assembly.

84522361 15/06/2011

C.20.F / 50

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Motor - Install L213, L215, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls, C227 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

DANGER Crushing hazard! Failure to engage the loader arm support pin could cause the loader arm to fall unexpectedly. Verify that the loader arm support pin is engaged. Failure to comply will result in death or serious injury. D0020A

1.

Apply a bead of LOCTITE® 598 ULTRA BLACK adhesive, (1), in corner between pilot and flange of motor, around diameter of pilot, similar to o-ring, (approximately 12.5 ml (0.4 US fl oz) per motor).

2.

Apply a 3 mm (0.1 in) bead around the outside of the bolt holes of the motor flange and 2 dabs per nut between the nut and motors.

3.

Use acceptable lifting equipment and move the drive motor/brake assembly (1) into the chassis mounting location (2). Refer to images one and two.

84522361 15/06/2011

C.20.F / 51

931001687A

1

931002004

2

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

4.

Install new mounting hardware (1) and torque to 122 N·m (90 lb ft) plus 60 degrees.

NOTE: DO NOT reuse motor mounting hardware after tightening to spec. Hardware is permanently stretched during tightening and must be discarded if loosened.

5.

Connect the hydraulic hoses (1) to hydrostatic drive motor to the correct ports

6.

Connect shift tube (on 2 speed equipped models).

84522361 15/06/2011

C.20.F / 52

931002085B

3

931002086

4

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

7.

8.

9.

Connect chains to drive sprocket

931002085B

5

931002083B

6

931002082B

7

Install front (1) and rear axle housings.

Install front and rear axle housing hardware (1) and Chain drive - Check (C)

84522361 15/06/2011

C.20.F / 53

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

10.

Install chain oil drain plug (1). oil level is approximately mid-way up the inspection cover. Cover must be installed before filling with oil.

11.

Install chain inspection cover (1) and mounting hardware (2)

12.

Fill chain tank to correct level and install check plug.

13.

14.

15.

931002081

8

931002080A

9

Install wheels (1) and wheel hardware (2)

931002070

10

931002069

11

Remove supports and lower skid steer

Disengage cab lock out and tilt cab down. See Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) for more information on Radial working arm units 84522361 15/06/2011

C.20.F / 54

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

16.

Install bucket refer to Bucket - Install (J.20.B)

84522361 15/06/2011

C.20.F / 55

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Motor - Remove track drive motor C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Prior operation: Rubber track - Remove (D.50.B) 1.

2.

Loosen and remove the upper and lower mounting bolts (1) which fasten the rear cover (2) to the main frame (3).

bs05c139_1

1

bs05c164_1

2

bs05c164_2

3

Apply vacuum to the reservoir. Refer to Reservoir Apply vacuum (A.10.A)

NOTE: Clean the hydraulic lines, fittings, and connectors and the area around motor connections to prevent dirt from entering the hydraulic system before the lines are disconnected from the motor. 3.

Loosen and remove all of the hydraulic lines that are connected to the drive motor. Place plugs in all of the lines.

4.

Stop the vacuum pump.

5.

Loosen and remove all of the connectors from the ports on the drive motor to allow room to slide the drive motor out of the main frame. Install clean plastic plugs into the ports (1) to avoid contamination.

6.

Make a reference mark on the drive motor (2) and the main frame (3) to be used for alignment of the drive motor during the installation procedure.

7.

Loosen and remove the mounting bolts (1) which fasten the drive motor (2) to the main frame (3).

8.

Slide the drive motor (2) out of the main frame (3) and place on the bench.

Next operation: Motor - Install track drive motor (C.20.F)

84522361 15/06/2011

C.20.F / 56

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Motor - Install track drive motor C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Prior operation: Motor - Remove track drive motor (C.20.F) 1.

2.

3.

Slide the drive motor (1) into the main frame (2) mounting location. If the same motor is being installed, use the marks made during removal and align the drive motor in the main frame. If a new motor is being installed, transfer the reference mark from the old motor to the same location on the new motor and align the drive motor in the main frame.

bs05c164_3

1

bs05c164_4

2

bs05c156_1

3

Install the mounting bolts (1) into the main frame.

Tighten the mounting bolts to an initial torque of 67 - 163 Nm (50 - 120 lb ft) using the star tightening sequence shown. After the initial torque is complete, tighten the mounting bolts to a final torque of 183 205 Nm (136 - 153 lb ft) using the star tightening sequence shown.

84522361 15/06/2011

C.20.F / 57

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

4.

Remove the plastic plugs from the motor ports (1). Install the connectors into the motor ports (1) and tighten the connectors.

5.

Apply vacuum to the reservoir. Refer to Reservoir Apply vacuum (A.10.A)

6.

Start the vacuum pump. Remove the caps from the lines and connect the lines to the drive motor. Tighten all of the hydraulic lines.

7.

Stop the vacuum pump and remove the vacuum pump from the reservoir.

8.

Install rubber tracks. Refer to Rubber track - Install (D.50.B)

9.

Start and run the engine at low idle for 2 to 5 minutes and check for any leaks.

10.

Stop the engine.

11.

Install the rear cover (2) onto the main frame (3). Install the upper and lower mounting bolts (1) into the rear cover (2). Tighten the mounting bolts (1).

12.

Check the oil level in the hydraulic reservoir and add hydraulic oil as required. Refer to : Reservoir - Filling (A.10.A)

84522361 15/06/2011

C.20.F / 58

bs05c164_1

4

bs05c139_1

5

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Sensing system - Remove Right hand swash plate sensor L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

4.

Locate the right hand swash plate sensor on the bottom of the electro-hydraulic hydrostatic pump (1).

931001814

1

931001961

2

931001961

3

Label and disconnect the connector from the swash plate sensor. The right hand swash plate sensor (1) is located on the input shaft side of the hydrostatic pump.

Remove the two screws (1) holding the swash plate shield (2) and sensor.

Remove the swash plate sensor.

84522361 15/06/2011

C.20.F / 59

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Sensing system - Install Right hand swash plate sensor L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

Install the right hand swash plate sensor (1).

931001961

1

931001961

2

Place the swash plate shield (2) over the right hand swash plate sensor. Insert the two screws (1) and tighten to proper torque.

84522361 15/06/2011

C.20.F / 60

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Sensing system - Remove Left hand swash plate sensor L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

4.

Locate the left hand swash plate sensor on the bottom of the electro-hydraulic hydrostatic pump (1).

931001814

1

931001961

2

931001961

3

Label and disconnect the connector from the swash plate sensor. The left hand swash plate sensor (1) is located near the auxiliary pump.

Remove the two screws (1) holding the swash plate shield (2) and sensor.

Remove the swash plate sensor.

84522361 15/06/2011

C.20.F / 61

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

Sensing system - Install Left hand swash plate sensor L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

Install the left hand swash plate sensor (1).

931001961

1

931001961

2

Place the swash plate shield (2) over the left hand swash plate sensor. Insert the two screws (1) and tighten to proper torque.

84522361 15/06/2011

C.20.F / 62

TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Hydrostatic

TRANSMISSION Hydrostatic - Troubleshooting Problem Possible Cause One Transmission (Right 1.If you have a EH unit perform EH pump or Left) Works Correctly electrical check and verify that unit has been properly calibrated. and the Other Does Not Check the interlock valve power/function. 2. Check the brake valve power/function. Make sure park brakes are released.

Machine does not have enough power

Correction A. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 2.

Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 3. 4. Check the charge pressure. Do - Checking the Charge Pressure/Flow. Refer to Charge pump - Pressure test (A.10.A) Charge pressure OK? Stroke the control lever. A 20 psi or greater drop indicates a leaky servo. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 4. Check the pressure setting of the circuit re- Do - Checking Circuit Relief Valve Preslief valve for the transmission with the prob- sure. Refer to Relief valve - Pressure test lem. (C.20.F) Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 5. 6. There is too much leakage in the hydrostatic system. Disassemble and inspect the hydrostatic pump and hydrostatic drive motors. 1. If you have a EH unit perform EH pump Is there still a problem? electrical check and verify that unit has No: Troubleshooting complete. been properly calibrated. Yes: Go to Step 2. Check the interlock valve power/function. 2. Full throttle engine speed is OK, rated A. Problem in engine or fuel system. Repair engine speed is low. as required. B. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 3. 3. Check charge pressure. Refer to Charge pump - Pressure test (A.10.A) Also check for damaged parts. Adjust pressure setting. A. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 4. 4. Faulty hydrostatic pump or hydrostatic A. Disassemble and inspect the hydrostatic drive motors. pump and hydrostatic drive motors. Repair as required.

84522361 15/06/2011

C.20.F / 63

Index TRANSMISSION, DRIVE AND PTO OUT - C TRANSMISSION Hydrostatic - 20.F Command - Install Left hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Command - Install Right hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Command - Remove Left hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Command - Remove Right hand drive solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Motor - General specification for 325cc 2 speed motor on medium frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L218, L220

Motor - General specification for EH and Mechanical 325cc single speed motor on medium and small frame models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 L213, L215, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls

Motor - General specification for EH and Mechanical 470cc 2 speed motor on medium and large frames . . . . . 15 L223, L225, L230

Motor - General specification for mechanical 470cc single speed motor on medium and large frames . . . . . . . . 13 L223, L225, L230

Motor - General specification for track drive 2 speed motor on medium and large frames . . . . . . . . . . . . . . . . . . . 16 C232, C238

Motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 L213, L215, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls, C227 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

Motor - Install track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 L213, L215, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Motor - Remove track drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Pump - General specification 46cc EH Hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L223, L225, L230, C227, C232, C238

Pump - Adjust Hydraulic Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 L220

Pump - Adjust Mechanical pump creep setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Pump - Adjust Servo Piston Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 L220

Pump - General specification 35cc EH Hydrostatic pump, used with small and medium frame models. . . . . . . . . 5 L213, L215, L218, L220

Pump - General specification 46cc EHF Hydrostatic pump, used with large frame models. . . . . . . . . . . . . . . . . . . . 7 L230, C238

Pump - General specification 46cc Hydrostatic tandem pump, used with large frame models. . . . . . . . . . . . . . . . 11 Pump - General specification 46cc Hydrostatic tandem pump, used with medium and large frame models. . . . . . 9 Pump - General specification 53cc hydrostatic pump, used with large frame models. . . . . . . . . . . . . . . . . . . . . . . . 10 Pump - General specification Mechanical controls 35cc Hydrostatic tandem pump, used with small and medium frame models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 L213, L215, L218, L220

Pump - Install EH hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Pump - Install mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Pump - Overview Hydrostatic pump model identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 84522361 15/06/2011

C.20.F / 64

Pump - Remove EH hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Pump - Remove mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Pump - Travel adjust (Stopping machine creep) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 L220

Relief valve - Pressure test (Machines Equipped with EH Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 L218, L220, L223, L225, L230, C227, C232, C238

Relief valve - Pressure test Ground Drive Relief Valve - Manual control models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L213, L215, L218, L220, L223, L225, L230

Sensing system - Install Left hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Sensing system - Install Right hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Sensing system - Remove Left hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Sensing system - Remove Right hand swash plate sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

TRANSMISSION Hydrostatic - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TRANSMISSION Hydrostatic - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

84522361 15/06/2011

C.20.F / 65

New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

84522361 15/06/2011 EN

SERVICE MANUAL AXLES, BRAKES AND STEERING

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

D

Contents AXLES, BRAKES AND STEERING - D

Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.15.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

Final drive Hydraulic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.15.C C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

STEERING Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.20.B 2 - Series

PARKING BRAKE Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.32.C C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

WHEELS AND TRACKS Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.50.B C227 , C232 , C238

WHEELS AND TRACKS Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.50.C C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

D

AXLES, BRAKES AND STEERING - D Final drive - 15.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

D.15.A / 1

Contents AXLES, BRAKES AND STEERING - D Final drive - 15.A

SERVICE Chain drive Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

D.15.A / 2

AXLES, BRAKES AND STEERING - Final drive

Chain drive - Check Check the tension of the four drive chains after the first 250 hours of operation on a new machine or if new chains have been installed and every 500 hours of operation. 1.

With the machine blocked up, rotate each tire and check for allowable movement. 6 - 12 mm (0.2 - 0.5 in) is the acceptable range.

63107489

1

931002280

2

93109317

3

Drive chain adjustment 2.

WARNING Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is possible. DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block wheels. Support machine with safety stands. Failure to comply could result in death or serious injury. W0069A

To adjust the final drive chains, jack up and block the complete skid steer securely off the ground. 3.

Each axle drive chain is adjustable by loosening the retaining nuts (1) (left front shown) and sliding the axle-hub assembly to remove the excessive slack. To tighten the chains slide the front axle-hubs forward and rear axle-hubs rearward. Torque the axle retaining hardware to 244 N·m (180 lb ft).

84522361 15/06/2011

D.15.A / 3

Index AXLES, BRAKES AND STEERING - D Final drive - 15.A Chain drive - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

D.15.A / 4

AXLES, BRAKES AND STEERING - D Final drive Hydraulic drive - 15.C

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

D.15.C / 1

Contents AXLES, BRAKES AND STEERING - D Final drive Hydraulic drive - 15.C

FUNCTIONAL DATA Command Overview 2 Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L218, L220, L223, L225, L230, C227, C232, C238

Overview Self Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview Glide Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

DIAGNOSTIC Command Testing Glide Ride Control Solenoid and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Testing 2 Speed Switch and Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L218, L220, L223, L225, L230, C227, C232, C238

Testing Self Level Switch and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84522361 15/06/2011

D.15.C / 2

AXLES, BRAKES AND STEERING - Final drive Hydraulic drive

Command - Overview 2 Speed Switch L218, L220, L223, L225, L230, C227, C232, C238

The button (1) on the left control handle switches the machine between first and second gear to increase or decrease ground speed. This feature will only be possible when all of the following conditions are met:

63109409

•

Operator is seated properly.

•

Seat belt is latched or lap bar is in the down position.

•

Hydraulics enabled is activated.

•

Park brake is not applied.

•

Ignition is on.

1

84522361 15/06/2011

D.15.C / 3

AXLES, BRAKES AND STEERING - Final drive Hydraulic drive

Command - Overview Self Level The automatic parallel-lift feature maintains a constant angle between the loader bucket / work-tool and the machine chassis as the loader arm is raised (one direction only). When in parallel lift mode, the loader operation is similar to that of a mechanical tool carrier linkage. Self level feature is engaged by pressing the On/Off switch mounted on left hand A post. The switch is illuminated when Self Level is on.

84522361 15/06/2011

D.15.C / 4

AXLES, BRAKES AND STEERING - Final drive Hydraulic drive

Command - Overview Glide Ride control Ride Control mode is enabled by a pressing a switch on the right hand joystick which opens a flow-path to an accumulator from the loader arm cylinders. This flow path enables the loader arm to be cushioned by absorbing the quick up and down motions of the machine as it travels across rough terrain. Ride Control is engaged by pressing the momentary on button. To disengage, by pressing the momentary button the second time. The Loader-Arm Ride Control feature is always active when the ignition is on.

84522361 15/06/2011

D.15.C / 5

AXLES, BRAKES AND STEERING - Final drive Hydraulic drive

Command - Testing Glide Ride Control Solenoid and Switch NOTE: Wiring Wiring Wiring

Use schematics harness - Electrical schematic frame 04 (A.30.A) harness - Electrical schematic frame 07 (A.30.A) harness - Electrical schematic frame 28 (A.30.A) (EH)

Test Point N° 1 Condition Disconnect connector X-RDCTRL from the RIDE CONTROL SOLENOID Y-010 Check for resistance between RIDE CONTROL SOLENOID pins 1 and 2. 2 Condition Disconnect connector X-406 (EH) X-402 (Mech) from the RIGHT HAND CONTROL HANDLE. Check Using a multi-meter, check for resistance between RIDE CONTROL / GLIDE RIDE SWITCH pins C and D (EH) pins C and D (Mech) while cycling the switch. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-RDCTRL pin 2 and ground. 4 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-RDCTRL pin 1 and connector X-406 pin D. 5 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-406 pin C (EH) X-402 pin 3 (Mech) and MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C4.

Expected Result Result Normal resistance. Action Go to test 2

Other Result (Possible Cause) Result 0 Ω, or greater than 1 K Ω Action The RIDE CONTROL SOLENOID has failed. Replace the solenoid.

Result For each resistance check, 0 Ω in one position, infinite resistance in the other. Action Go to test 3

Result 0 Ω in all positions or infinite resistance in all positions. Action The RIDE CONTROL / GLIDE RIDE SWITCH has failed. Replace the RIGHT HAND CONTROL HANDLE.

Result No wire problems. Action Go to test 4

Result Wire problems are found. Action Locate and repair or replace broken wire 951/964/967 (Black) adjacent wiring.

Result No wire problems. Action Go to test 5

Result Wire problems are found. Action Locate and repair or replace broken wire 831 (White) or adjacent wiring.

Result No wire problems. Action There is a problem in the DC distribution system upstream of IGNITION FUSE.

Result Wire problems are found. Action Locate and repair or replace broken wire 832/357/351 (Orange) or adjacent wiring.

84522361 15/06/2011

D.15.C / 6

AXLES, BRAKES AND STEERING - Final drive Hydraulic drive

Command - Testing 2 Speed Switch and Indicator L218, L220, L223, L225, L230, C227, C232, C238

NOTE: Wiring Wiring Wiring

Use schematics harness - Electrical schematic frame 04 (A.30.A) harness - Electrical schematic frame 07 (A.30.A) harness - Electrical schematic frame 14 (A.30.A)

Test Point N° 1 Condition Remove IGNITION FUSE from the MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008. Check for continuity across IGNITION FUSE. 2 Condition With the fuse removed and ignition on, Check for voltage from MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C3 and ground. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-408 pin 4 (EH) X-405 pin A (Mech) and MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C4. 4 Check Using a multi-meter, check for resistance across 2 SPEED SWITCH S-024 while cycling the switch.

Expected Result Result 0Ω Action Go to test 2

Other Result (Possible Cause) Result Fuse is blown. Action Replace the fuse with same type and amp rating.

Result 12 V Action Go to test 3

Result 0V Action There is a problem in the DC distribution system upstream of IGNITION FUSE.

Result No wire problems. Action Go to test 4

Result Wire problems are found. Action Locate and repair or replace broken wire 891/357/351 (Orange) or adjacent wiring.

Result 0 Ω in all positions or infinite resistance in all positions. Action The 2 SPEED SWITCH has failed. Replace the LEFT HAND CONTROL HANDLE. 5 Condition Result Result No change in circuit response, reDisconnect connector X-310 from No circuit problems. move jumper. the 2-SPEED INDICATOR. Connect a Action jumper between connector X-310 The 2-SPEED INDICATOR has failed. Action Go to test 6 Replace the indicator. pins 7 and 9. Check Check circuit operation. Result Result 6 Condition Wire problems are found. Use ELECTRICAL POWER SYS- No wire problems. Action TEM - Testing General Wire Test- Action Locate and repair or replace broken Go to test 7 ing (A.30.A) to wire 563 (White) / 565 (Violet) or adCheck jacent wiring. wire condition between connector X-408 pin 9 (EH) X-405 pin D (Mech) and connector X-310 pin 7. 7 Condition Result Result Wire problems are found. Use ELECTRICAL POWER SYS- No wire problems. Action TEM - Testing General Wire Test- Action Locate and repair or replace broing (A.30.A) to See the following for further testing ken wire 917/941/942/1094 (Black) Check wire condition between connector • Command - Testing or adjacent wiring. X-310 pin 9 and ground. Glide Ride Control Solenoid and Switch (D.15.C) Result For each resistance check, 0 Ω in one position, infinite resistance in the other. Action Go to test 5

84522361 15/06/2011

D.15.C / 7

AXLES, BRAKES AND STEERING - Final drive Hydraulic drive

Command - Testing Self Level Switch and Valve NOTE: Wiring Wiring Wiring

Use schematics harness - Electrical schematic frame 02 (A.30.A) harness - Electrical schematic frame 04 (A.30.A) harness - Electrical schematic frame 06 (A.30.A)

Test Point N° 1 Condition Remove ACCESSORY FUSE from the MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008. Check for continuity across ACCESSORY FUSE. 2 Condition With the fuse removed and Ignition on, Check for voltage from MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C1 and ground. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-317 pin B and MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C2. 4 Condition Disconnect connector X-317 from the SELF LEVEL SWITCH S-013. Check Using a multi-meter, check for resistance between SELF LEVEL SWITCH pins A and B while cycling the switch. 5 Condition Disconnect connector X-318 from the SELF LEVEL VALVE Y-318. Reconnect all other connectors. Connect a jumper between connector X-318 pins 1 and 2. Check Check circuit operation. 6 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-318 pin 2 and ground.

Expected Result Result 0Ω Action Go to test 2

Other Result (Possible Cause) Result Fuse is blown. Action Replace the fuse with same type and amp rating.

Result 12 V Action Go to test 3

Result 0V Action There is a problem in the DC distribution system upstream of ACCESSORY FUSE.

Result No wire problems. Action Go to test 4

Result Wire problems are found. Action Locate and repair or replace broken wire 405/134 (Orange) or adjacent wiring.

Result For each resistance check, 0 Ω in one position, infinite resistance in the other. Action Go to test 5

Result 0 Ω in all positions or infinite resistance in all positions. Action The SELF LEVEL SWITCH has failed. Replace the switch.

Result Result No change in circuit response, reNo circuit problems. move jumper. Action The SELF LEVEL VALVE has failed. Action Go to test 6 Replace the valve.

Result No wire problems. Action The fault may be intermittent. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. If no damage is found, continue operation.

84522361 15/06/2011

D.15.C / 8

Result Wire problems are found. Action Locate and repair or replace broken wire 949/964/967 (Black) or adjacent wiring.

Index AXLES, BRAKES AND STEERING - D Final drive Hydraulic drive - 15.C Command - Overview 2 Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L218, L220, L223, L225, L230, C227, C232, C238

Command - Overview Glide Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Command - Overview Self Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Command - Testing 2 Speed Switch and Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L218, L220, L223, L225, L230, C227, C232, C238

Command - Testing Glide Ride Control Solenoid and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Command - Testing Self Level Switch and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84522361 15/06/2011

D.15.C / 9

84522361 15/06/2011

D.15.C / 10

AXLES, BRAKES AND STEERING - D STEERING Mechanical - 20.B

2 - Series

84522361 15/06/2011

D.20.B / 1

Contents AXLES, BRAKES AND STEERING - D STEERING Mechanical - 20.B

SERVICE STEERING Mechanical Adjust for hand controls with direct mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Adjust hand controls with servo operated pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 C227 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

Adjust Float Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

84522361 15/06/2011

D.20.B / 2

AXLES, BRAKES AND STEERING - STEERING Mechanical

STEERING Mechanical - Adjust for hand controls with direct mechanical hydrostatic pump L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Adjustment preparation for hand controls 1.

Raise machine off ground and place securely on jack stands

2.

Check spring caps to make sure they are pushing against centering plate and there is no gap between jam nuts and spring caps.

3.

If there is any gap, loosen all 4 nuts and adjust

23112911

1

23112912

2

23112912

3

Adjustment for hand controls 1.

Loosen Jam Nut (1).

2.

Take engine to high idle.

3.

Turn rod /spring assembly (2) until wheels just turn in forward direction.

4.

Turn rod (2) in opposite direction until wheels just rotate in reverse direction. Count number of turns of rod from forward motion to reverse.

5.

Turn the rod back ½ the number of turns recorded in the step prior.

6.

Tighten jam nut (1) .

7.

Move handle in both directions to confirm neutral is set. Adjust if needed.

8.

Repeat steps 4-7 for other pump. Please note the differences between the right and left sides, as shown in images 2 and 3. Keep these differences in mind when repeating steps 4-7.

84522361 15/06/2011

D.20.B / 3

AXLES, BRAKES AND STEERING - STEERING Mechanical

9.

10.

After Creep has been set use control rods (1) to set handle position, by loosening the left hand side jam nut (2) and right hand side jam nut (3). Rotate rod (1) until the handle is in the correct position, and tighten jam nuts (2) and (3).

23112913

4

23112914

5

Factory setting is 75 ° represented by (X).

Adjusting stop bolts. NOTE: Images may or may not represent your exact machine configuration. This procedure is the same for all mechanically operated machines in any configuration. 11.

Turn stop bolt (1) out several turns.

12.

Push handle (2) full forward until pump is fully stroked, hold handle in this position and turn stop bolt in until it just contacts casting.

13.

Repeat for other side

23112915

84522361 15/06/2011

D.20.B / 4

6

AXLES, BRAKES AND STEERING - STEERING Mechanical

14.

Operate machine – Record Drift

15.

Use stop bolt to slow down fast side of machine.

23112916

NOTE: Stop bolt should just contact casting when pump is at full stroke.

84522361 15/06/2011

D.20.B / 5

7

AXLES, BRAKES AND STEERING - STEERING Mechanical

STEERING Mechanical - Adjust hand controls with servo operated pump C227 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

1.

Loosen bolts (1) attaching the self centering dampeners

2.

Use the control rods to set handle position. First, loosen the left hand side jam nut (3) and right hand side jam nut (4). Rotate rod (2) until the handle is in the correct position and then tighten both jam nuts (3) and (4).

3.

Tighten bolts attaching the self centering dampeners.

4.

Repeat for other pump.

5.

Set stop bolts and drift – same as direct mechanical. STEERING Mechanical - Adjust for hand controls with direct mechanical hydrostatic pump (D.20.B)

6.

After drift is set, adjust forward stop bolts on the pump that was NOT adjusted in step 5, so that the handles are aligned side to side when pushed full ahead. Take note not to adjust the stop bolt to the point where that side of the machine has slowed down. This step should only reduce the dead band at the end of handle stroke and not effect travel speed.

84522361 15/06/2011

D.20.B / 6

23112921

1

AXLES, BRAKES AND STEERING - STEERING Mechanical

STEERING Mechanical - Adjust Float Detent L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

1.

Angle between lift control rod and ear on jackshaft must be 90 °or less when spoon is in neutral.

2.

If angle is greater then 90 ° increase length of rod by turning out the clevis ends on rod.

3.

4.

23112922A

1

23112923

2

23112924

3

If length of rod from ear on jackshaft to valve spool is increased, the grip will need to be repositioned by adjusting connecting rod.

If detent still does not hold check clearance between rod end and pivot. If rod end is hitting, shorten connecting rod between grip and jack shaft. After decreasing length of connecting rod, you must check to confirm grip does not hit window or side screen during full raise.

84522361 15/06/2011

D.20.B / 7

Index AXLES, BRAKES AND STEERING - D STEERING Mechanical - 20.B STEERING Mechanical - Adjust for hand controls with direct mechanical hydrostatic pump . . . . . . . . . . . . . . . . . . 3 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

STEERING Mechanical - Adjust Float Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

STEERING Mechanical - Adjust hand controls with servo operated pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 C227 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

84522361 15/06/2011

D.20.B / 8

AXLES, BRAKES AND STEERING - D PARKING BRAKE Hydraulic - 32.C

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

D.32.C / 1

Contents AXLES, BRAKES AND STEERING - D PARKING BRAKE Hydraulic - 32.C

TECHNICAL DATA Control valve General specification of the EH track brake valve on medium and large frame . . . . . . . . . . . . . . . . . . . . . . 4 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

General specification of the EH 2 speed brake valve on medium and large frame . . . . . . . . . . . . . . . . . . . 4 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls

General specification 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L218, L220, L223, L225, L230

General specification of the EH single speed brake valve on small frame . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L213, L215

General specification of the Mechanical single speed brake valve on all frames except track models . . 8

FUNCTIONAL DATA Electrical control Overview Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Command Remove Brake valve solenoid for models with single speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install Brake valve solenoid for models with single speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove 2speed solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 L218, L220, L223, L225, L230, C227, C232, C238

Install 2speed solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 L218, L220, L223, L225, L230, C227, C232, C238

Remove Loader pilot interlock valve solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Install Loader pilot interlock valve solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Remove Brake valve solenoid for models equipped with EH brake valve/EH 2speed brake valve/EH track brake valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

D.32.C / 2

Install Brake valve solenoid for models equipped with EH brake valve/EH 2speed brake valve/EH track brake valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control valve Remove EH 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 L218, L220, L223, L225, L230, C227, C232, C238

Install EH 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L218, L220, L223, L225, L230, C227, C232, C238

Remove EH brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 L213, L215

Install EH brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 L213, L215

Remove 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 L218, L220, L223, L225, L230

Install 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 L218, L220, L223, L225, L230

Remove Brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Install Brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Sensing system Pressure sensor - Remove Charge pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Pressure sensor - Install Charge pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

D.32.C / 3

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Control valve - General specification of the EH track brake valve on medium and large frame C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Brake Solenoid Valve Configuration: 2 Speed Solenoid Valve Configuration: EH Interlock Solenoid Valve Configuration: Hydraulic Requirements:

Electrical Requirements:

Pressure Switch Requirements:

Operating Temperature Range: Port Identification Chart:

Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic cartridge valve. Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic cartridge valve. Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic cartridge valve. Flow = 7.6 l/min (2 US gpm) Charge Pressure = 25 bar (363 psi) Brake Release Pressure = 15 bar (218 psi) Operating Voltage = 14 V Maximum Power = 22 W Polarity = Power: Pin 1 or A, Ground: Pin 2 or B Brake Release Solenoid Connection Type: Deutsch DT series. 2 Speed Solenoid Connection Type :Packard Metri - Pack 150 Series EH Interlock Release Solenoid Connection Type: Packard Metri - Pack 150 series . Operating Voltage = 14 V Maximum Current = 2 A @ 12 V nominal. Switch is normally open Switch opening pressure settings: 15.5 bar (225 psi) -30 - 107 °C (-22 - 225 °F) (P) Supply Inlet (T) Tank Return (B1) Brake Motor 1 (B2) Brake Motor 2 (2 SPD) 2 Speed Shift (LV) EH Pilot Pressure (PS1) Charge Pressure Switch (PS2) Brake Pressure Switch

Control valve - General specification of the EH 2 speed brake valve on medium and large frame L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls

Brake Solenoid Valve Configuration: 2 Speed Solenoid Valve Configuration: EH Interlock Solenoid Valve Configuration: Hydraulic Requirements:

Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic cartridge valve. Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic cartridge valve. Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic cartridge valve. Flow = 7.6 l/min (2 US gpm) Charge Pressure = 25 bar (363 psi) Brake Release Pressure = 15 bar (218 psi) Sequence Valve Pressure = 12 bar (174 psi)

84522361 15/06/2011

D.32.C / 4

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Electrical Requirements:

Pressure Switch Requirements:

Operating Temperature Range: Port Identification Chart:

Operating Voltage = 14 V Maximum Power = 22 W Polarity = Power: Pin 1 or A, Ground: Pin 2 or B Brake Release Solenoid Connection Type: Deutsch DT series . 2 Speed Solenoid Connection Type :Packard Metri - Pack 150 Series EH Interlock Release Solenoid Connection Type: Packard Metri - Pack 150 Series . Operating Voltage = 14 V Maximum Current = 2 A @ 14 V nominal. Switch is normally open Switch opening pressure settings: 15.5 bar (225 psi) -30 - 107 °C (-22 - 225 °F) (P) Supply Inlet (T) Tank Return (B1) Brake Motor 1 (B2) Brake Motor 2 (SPD) 2 Speed Shift (LV) EH Pilot Pressure (PS1) Charge Pressure Switch (PS2) Brake Pressure Switch

84522361 15/06/2011

D.32.C / 5

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Control valve - General specification 2speed brake valve L218, L220, L223, L225, L230

Brake Solenoid Valve Configuration: 2 Speed Solenoid Valve Configuration: Hydraulic Requirements:

Electrical Requirements:

Operating Temperature Range: Port Identification Chart:

Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic cartridge valve. Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic cartridge valve. Flow = 7.6 l/min (2 US gpm) Charge Pressure = 25 bar (363 psi) Brake Release Pressure = 15 bar (218 psi) Operating Voltage = 14 V Maximum Power = 22 W Polarity = Power: Pin 1 or A, Ground: Pin 2 or B Brake Release Solenoid Connection Type: Deutsch DT series . 2 Speed Solenoid Connection Type: Packard Metri - Pack 150 Series must -30 - 107 °C (-22 - 225 °F) (P) Supply Inlet (T) Tank Return (B1) Brake Motor 1 (B2) Brake Motor 2 (SPD) 2 Speed Shift

84522361 15/06/2011

D.32.C / 6

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Control valve - General specification of the EH single speed brake valve on small frame L213, L215

Brake Solenoid Valve Configuration:

Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic cartridge valve.

EH Interlock Solenoid Valve Configuration:

Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic cartridge valve.

Hydraulic Requirements:

Flow = 7.6 l/min (2 US gpm) Charge Pressure = 25 bar (363 psi) Brake Release Pressure = 15 bar (218 psi)

Electrical Requirements:

Operating Voltage = 14 V Maximum Power = 22 W Minimum On-Off Duty Cycle = 50,000 cycles Polarity = Power: Pin 1 or A, Ground: Pin 2 or B Brake Release Solenoid Connection Type: Deutsch DT series. EH Interlock Release Solenoid Connection Type: Packard Metri - Pack 150 series.

Pressure Switch Requirements:

Operating Voltage = 14 V Maximum Current = 2 A @ 14 V nominal. Voltage Drop: 50 mV @ 2 A Switch is normally open Switch opening pressure settings: 15.5 bar (225 psi)

Operating Temperature Range:

-30 - 107 °C (-22 - 225 °F)

Port Identification Chart:

(P) Supply Inlet (T) Tank Return (B1) Brake Motor 1 (B2) Brake Motor 2 (LV) EH Pilot Pressure (PS1) Charge Pressure Switch (PS2) Brake Pressure Switch

84522361 15/06/2011

D.32.C / 7

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Control valve - General specification of the Mechanical single speed brake valve on all frames except track models Brake Solenoid Valve Configuration: Hydraulic Requirements:

Solenoid operated, 3 way, 2 way position, direct acting, spool type hydraulic cartridge valve. Flow = 7.6 l/min (2 US gpm) Charge Pressure = 25 bar (363 psi) Brake Release Pressure = 15 bar (218 psi)

Electrical Requirements:

Operating Voltage = 14 V Maximum Power = 22 W Polarity = Power: Pin 1 or A, Ground: Pin 2 or B Brake Release Solenoid Connection Type: Deutsch DT series.

Operating Temperature Range: Port Identification Chart:

-30 - 107 °C (-22 - 225 °F) (P) Supply Inlet (T) Tank Return (B1) Brake Motor 1 (B2) Brake Motor 2

84522361 15/06/2011

D.32.C / 8

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Electrical control - Overview Park Brake The park brake enable switch allows the operator to turn on and off the park brake after the hydraulics are enabled. The switch is located in the RH Console. The button engages and disabling the ground drive brake system. The parking brake can be engaged independent of the loader valve by a park brake switch on the joystick. The button will only toggle the park brake on and off if the master enable switch is on. A LED will indicate that the park brake is on and the hydraulics enable has enabled the machine. The park brake switch can be activated when 1.

Operator is seated properly

2.

The seat belt is latched or lap bar in down position while operator in seat

3.

The ignition is on

4.

Hydraulics are enabled

84522361 15/06/2011

D.32.C / 9

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Command - Remove Brake valve solenoid for models with single speed 1.

2.

3.

Locate the single speed brake valve, on the floor left side, underneath the operator's cab.

93111536

1

931001725A

2

931001725A

3

Remove the electrical connector (1) from the brake valve solenoid.

Unthread the cap (1) and slide the solenoid off.

84522361 15/06/2011

D.32.C / 10

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Command - Install Brake valve solenoid for models with single speed 1.

2.

Place solenoid (1) onto valve block . Thread cap (2) onto valve body.

931001725A

1

931001725A

2

Connect the electrical connector (2) to the solenoid.

84522361 15/06/2011

D.32.C / 11

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Command - Remove 2speed solenoid L218, L220, L223, L225, L230, C227, C232, C238

1.

2.

3.

4.

Locate the brake valve (1) on the floor. Located in the front left corner, under the operator's seat.

931001728

1

931001728

2

931001725A

3

Disconnect the connector (2) from the 2speed solenoid (1).

Unthread the cap (1) from the solenoid.

Slide the solenoid off.

84522361 15/06/2011

D.32.C / 12

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Command - Install 2speed solenoid L218, L220, L223, L225, L230, C227, C232, C238

1.

2.

Slide the 2speed solenoid onto the valve body. Thread cap (1) onto valve body.

931001727

1

931001728

2

Connect the connector (2) to the 2speed solenoid (1).

84522361 15/06/2011

D.32.C / 13

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Command - Remove Loader pilot interlock valve solenoid L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

NOTE: This procedure can be used on models with EH 2speed brake valve or track models with EH track brake valve. 1.

2.

3.

4.

Locate the brake valve (1) on the floor. Located in the front left corner, under the operator's seat.

93111535

1

931001727

2

93111535

3

Disconnect the connector (1) from the pilot interlock solenoid.

Unthread cap (1) from the solenoid.

Slide the solenoid off.

84522361 15/06/2011

D.32.C / 14

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Command - Install Loader pilot interlock valve solenoid L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

Slide the solenoid onto the valve body. Thread cap (1) onto the valve body.

93111535

1

931001727

2

Connect the connector (1) to the pilot interlock solenoid.

84522361 15/06/2011

D.32.C / 15

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Command - Remove Brake valve solenoid for models equipped with EH brake valve/EH 2speed brake valve/EH track brake valve. L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

Locate the brake valve (1) on the floor. Located in the front left corner, under the operator's seat.

93111535

1

931001725A

2

931001725A

3

Remove the electrical connector (1) from the brake valve solenoid.

NOTE: The brake valve solenoid can be determined from looking at the brake valve body. The ports for the brake valve are labeled B1 and B2

3.

Unthread the cap (1) and slide the solenoid off.

84522361 15/06/2011

D.32.C / 16

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Command - Install Brake valve solenoid for models equipped with EH brake valve/EH 2speed brake valve/EH track brake valve. L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

Slide the solenoid onto the valve body. Thread the cap (1) onto the valve body.

931001725A

1

931001725A

2

Connect the electrical connector (1) to the brake valve solenoid.

NOTE: The brake valve solenoid can be determined from looking at the brake valve body. The ports for the brake valve are labeled B1 and B2

84522361 15/06/2011

D.32.C / 17

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Control valve - Remove EH 2speed brake valve L218, L220, L223, L225, L230, C227, C232, C238

1.

2.

3.

4.

Label and disconnect hydraulic hose (1) from back side of valve.

931001727

1

931001726

2

931001726

3

931001731

4

Label and disconnect four hoses (A), (B), (C), (D) and one tube (E) from right hand side of valve.

Label and disconnect the drain hose (2).

Label and disconnect five electrical connections, as shown.

84522361 15/06/2011

D.32.C / 18

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

5.

6.

Remove mounting hardware (3).

931001728

5

931001729

6

Remove valve.

84522361 15/06/2011

D.32.C / 19

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Control valve - Install EH 2speed brake valve L218, L220, L223, L225, L230, C227, C232, C238

1.

Locate correct position on body to mount valve.

2.

Install mounting hardware (1).

NOTE: There is two mounting bolts securing the valve.

3.

4.

5.

931001728

1

931001731

2

931001726

3

931001728

4

Connect the five electrical connections to the correct outlets as previously labeled.

Connect drain hose (2).

Connect the four hoses (A), (B), (C), (D) and one tube (E) to the correct locations as previously labeled.

84522361 15/06/2011

D.32.C / 20

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

6.

Connect hydraulic hose (3) to the back side of valve.

931001727

84522361 15/06/2011

D.32.C / 21

5

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Control valve - Remove EH brake valve L213, L215

1.

2.

3.

4.

Label and disconnect hydraulic hose (1) from back side of valve. Cap open ports.

931001727

1

931001727

2

931001728

3

931001726AA

4

Label and disconnect switch connections (1) on the brake valve.

Label and disconnect solenoid connections (1) on the brake valve.

Label and disconnect hoses (1) from valve. Cap open ports.

84522361 15/06/2011

D.32.C / 22

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

5.

6.

7.

Label and disconnect the drain hose (1). Cap open ports.

931001726AA

5

931001728

6

931001729A

7

Remove mounting hardware (1).

Remove valve.

84522361 15/06/2011

D.32.C / 23

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Control valve - Install EH brake valve L213, L215

1.

2.

3.

4.

Place brake valve into machine, left front corner on the floor.

931001729A

1

931001728

2

931001726AA

3

931001726AA

4

Insert mounting hardware (1).

Connect the drain hose (1).

Connect hoses (1) to the valve.

84522361 15/06/2011

D.32.C / 24

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

5.

6.

7.

Connect solenoid (1) connections onto the brake valve.

931001728

5

931001727

6

931001727

7

Connect switch connections (1) onto the brake valve.

Connect the hydraulic hose (1) to the back side of valve.

84522361 15/06/2011

D.32.C / 25

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Control valve - Remove 2speed brake valve L218, L220, L223, L225, L230

Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

Label and disconnect hydraulic hose (1) from back side of valve. Cap open ports.

931001727

1

931001728

2

931001726AA

3

Label and disconnect solenoid connections (1) on the brake valve.

Label and disconnect hoses (1) from valve. Cap open ports.

84522361 15/06/2011

D.32.C / 26

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

4.

5.

6.

Label and disconnect the drain hose (1). Cap open ports.

931001726AA

4

931001728

5

931001729A

6

Remove mounting hardware (1).

Remove valve.

84522361 15/06/2011

D.32.C / 27

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Control valve - Install 2speed brake valve L218, L220, L223, L225, L230

1.

2.

3.

4.

Place brake valve into machine, left front corner on the floor.

931001729A

1

931001728

2

931001726AA

3

931001726AA

4

Insert mounting hardware (1).

Connect the drain hose (1).

Connect hoses (1) to the valve.

84522361 15/06/2011

D.32.C / 28

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

5.

6.

7.

Connect solenoid connections (1) onto the brake valve.

931001728

5

931001727

6

Connect the hydraulic hose (1) to the back side of valve.

Lower cab and lift arms refer to Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A)

84522361 15/06/2011

D.32.C / 29

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Control valve - Remove Brake valve L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

Label and disconnect hydraulic hose (1) from back side of valve. Cap open ports.

931001726B

1

931001725A

2

931001726C

3

Label and disconnect solenoid connections (1) on the brake valve.

Label and disconnect hoses (1) from valve. Cap open ports.

84522361 15/06/2011

D.32.C / 30

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

4.

5.

6.

Label and disconnect the drain hose (1). Cap open ports.

931001726C

4

931001726B

5

931001729B

6

Remove mounting hardware (1).

Remove valve.

84522361 15/06/2011

D.32.C / 31

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Control valve - Install Brake valve L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

1.

2.

3.

4.

Place valve onto floor of machine, front left floor.

931001729B

1

931001726B

2

931001726C

3

931001726C

4

Insert and tighten mounting hardware (1).

Connect the drain hose (1).

Connect hoses (1) to valve.

84522361 15/06/2011

D.32.C / 32

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

5.

6.

Connect solenoid connector (1) to the brake valve solenoid.

931001725A

5

931001726B

6

Connect hydraulic hose (1) to the back side of valve.

84522361 15/06/2011

D.32.C / 33

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Sensing system Pressure sensor - Remove Charge pressure switch L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

NOTE: Removing the charge pressure switch is the same procedure for the EH brake valve and EH 2speed brake valve. This procedure uses the EH 2speed brake valve. 1.

2.

3.

Locate the brake valve.

931002289

1

931001731

2

Locate the charge pressure switch, port PS1. Disconnect the connector (1) from the harness.

Unscrew the pressure sensor from the valve body.

84522361 15/06/2011

D.32.C / 34

AXLES, BRAKES AND STEERING - PARKING BRAKE Hydraulic

Sensing system Pressure sensor - Install Charge pressure switch L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

NOTE: Installing the charge pressure switch is the same procedure for the EH brake valve and EH 2speed brake valve. This procedure uses the EH 2speed brake valve. 1.

Thread and tighten the charge pressure switch into the brake valve body port PS1.

2.

Connect the charge pressure connector to the electrical harness.

931001731

84522361 15/06/2011

D.32.C / 35

1

Index AXLES, BRAKES AND STEERING - D PARKING BRAKE Hydraulic - 32.C Command - Install Brake valve solenoid for models equipped with EH brake valve/EH 2speed brake valve/EH track brake valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Command - Install Brake valve solenoid for models with single speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Command - Install 2speed solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 L218, L220, L223, L225, L230, C227, C232, C238

Command - Install Loader pilot interlock valve solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Command - Remove Brake valve solenoid for models equipped with EH brake valve/EH 2speed brake valve/EH track brake valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Command - Remove Brake valve solenoid for models with single speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Command - Remove 2speed solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 L218, L220, L223, L225, L230, C227, C232, C238

Command - Remove Loader pilot interlock valve solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control valve - General specification 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L218, L220, L223, L225, L230

Control valve - General specification of the EH 2 speed brake valve on medium and large frame . . . . . . . . . . . . . 4 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls

Control valve - General specification of the EH single speed brake valve on small frame . . . . . . . . . . . . . . . . . . . . . 7 L213, L215

Control valve - General specification of the EH track brake valve on medium and large frame . . . . . . . . . . . . . . . . 4 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control valve - General specification of the Mechanical single speed brake valve on all frames except track models .................................................................................................. 8 Control valve - Install 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 L218, L220, L223, L225, L230

Control valve - Install Brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Control valve - Install EH 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L218, L220, L223, L225, L230, C227, C232, C238

Control valve - Install EH brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 L213, L215

Control valve - Remove 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 L218, L220, L223, L225, L230

Control valve - Remove Brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Control valve - Remove EH 2speed brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 L218, L220, L223, L225, L230, C227, C232, C238

Control valve - Remove EH brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 L213, L215

Electrical control - Overview Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Sensing system Pressure sensor - Install Charge pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Sensing system Pressure sensor - Remove Charge pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

D.32.C / 36

AXLES, BRAKES AND STEERING - D WHEELS AND TRACKS Tracks - 50.B

C227 C232 C238

84522361 15/06/2011

D.50.B / 1

Contents AXLES, BRAKES AND STEERING - D WHEELS AND TRACKS Tracks - 50.B

SERVICE Drive sprocket Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Rubber track Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Track tensioning mechanism Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Track adjustment mechanism Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C227, C232, C238

Roller - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Idler wheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

D.50.B / 2

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

Drive sprocket - Remove C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

Prior operation: Refer to Rubber track - Tension adjust (D.50.B) and completely loosen the tension on the track. Make reference marks on the cover (1) and the drive sprocket (2) to be used for alignment and the bolt torque procedure during installation.

231002477A

1

231002477A

2

Loosen and remove the socket head cap screws (1) from the drive sprocket (2). Use acceptable lifting equipment and lift the track above the drive sprocket to allow the guide teeth to disengage from the drive sprocket. Slide the drive sprocket off of the hub and remove the drive sprocket.

84522361 15/06/2011

D.50.B / 3

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

Drive sprocket - Install C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

NOTE: Photos are for reference only. Photo shows socket head cap screws installed on the drive sprocket. 1.

2.

3.

4.

Slide the drive sprocket over the hub. If the same sprocket that was removed is being installed, use the alignment marks made during removal to align the drive sprocket on the hub. Lift the track above the drive sprocket to allow the drive sprocket to engage the guide teeth (1) on the track. Make sure the drive sprocket is between the guide teeth (1) on the track.

231002477A

1

231002477A

2

231002477A

3

231002477A

4

Install the socket head cap screws (1) into the drive sprocket (2).

Use the reference mark on the hub as the starting point and tighten the socket head cap screws to a torque of 67 - 163 Nm (50 - 120 lb ft) in the sequence shown.

Tighten the socket head cap screws to a final torque of 285 - 320 Nm (208 - 235 lb ft) in the sequence shown. Next operation: After the drive sprocket has been installed, follow the procedure - Rubber track - Tension adjust (D.50.B) and adjust the tension of the track.

84522361 15/06/2011

D.50.B / 4

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

Rubber track - Remove C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

Park the machine on a level surface with the bucket approximately 125 mm (5 in) off of the ground and stop the engine.

2.

Place 101 mm (4 in) blocks on the ground under the bucket. Enter the operators compartment and start the engine and lower the bucket until the front of the machine is raised off the ground. Stop the engine and exit the operators compartment. Place a floor jack under the rear of the machine and raise the rear of the machine until the tracks are completely off of the ground. Install blocks under the machine to securely block the machine in the raised position with the tracks off the ground.

3.

Remove the screws (1) from the adjuster cover (2) and remove the cover.

4.

231002469

1

231002468A

2

231002478

3

Slowly loosen the grease valve (1) on the adjuster (2) until the grease begins to discharge from the adjuster (2). Allow the grease to completely discharge from the adjuster (2) to release the tension on the track as the idler wheel moves rearward.

NOTE: DO NOT remove the grease valve body from the adjuster. Internal parts (ball, spring, and poppet) may be lost.

84522361 15/06/2011

D.50.B / 5

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

5.

6.

7.

The idler wheel (1) can be moved farther rearward either by pushing the idler wheel rearward or by lifting on the center (2) of the track.

231002469

4

231002469

5

231002469

6

Lift the track (2) off of the drive sprocket (1) to allow room for the drive sprocket (1) to slide off of the hub. Next operation: Refer to Drive sprocket - Remove (D.50.B) and remove the drive sprocket (1).

Remove the rubber track from the main frame (2)

84522361 15/06/2011

D.50.B / 6

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

Rubber track - Install C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

3.

Follow the procedure in Steps 1 and 2 of Rubber track - Remove (D.50.B) and raise and install blocks under the machine to securely block the machine in the raised position so that the tracks are off the ground.

231002469

1

231002473

2

231002474

3

Install the track around the rear idler wheel (1). Make sure the rear idler wheel is between the guide teeth (2) on the track.

Continue towards the front idler wheel (1) engaging the track guide teeth (3) between the rollers (2) and then around the front idler wheel (1). Make sure the front idler wheel (1) is between the guide teeth (3) on the track. Next operation: Refer to Drive sprocket - Install (D.50.B) and install the drive sprocket. Next operation: Refer to Rubber track - Tension adjust (D.50.B) and adjust the tension of the track.

84522361 15/06/2011

D.50.B / 7

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

Rubber track - Tension adjust C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

3.

4.

Follow the procedure in Steps 1 and 2 of Rubber track - Remove (D.50.B) and raise and install blocks under the machine to securely block the machine in the raised position so that the tracks are off the ground.

231002469

1

231002468A

2

231002478

3

231002478

4

Remove the screws (1) from the adjuster cover (2) and remove the cover (2).

Tighten the grease valve (1) to a torque of 90 ± 10 Nm (66 ± 10 lb ft). Install a power grease gun on the grease zerk (3) on the grease valve (1).

To tighten the track, apply grease to the adjuster (2) to increase the tension to the track.

84522361 15/06/2011

D.50.B / 8

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

5.

Apply grease to the adjuster until the distance from the bottom of the 2 center rollers (1) to the top surface (2) of the track is within 12 - 19 mm (0.47 - 0.75 in)

231002475

6.

To loosen the track, loosen the grease valve on the adjuster until grease discharges from the adjuster. Allow the grease to discharge from the adjuster until the distance from the bottom of the two center rollers to the top surface of the track is within 12 - 19 mm (0.47 - 0.75 in) as shown in the step above. When the distance is within the specifications, tighten the grease valve to a torque of 90 ± 10 Nm (66 ± 10 lb ft) .

NOTE: DO NOT remove the grease valve body from the adjuster. Internal parts (ball, spring, and poppet) may be lost.

84522361 15/06/2011

D.50.B / 9

5

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

Track tensioning mechanism - Remove C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Prior operation: Refer to Rubber track - Remove (D.50.B) and remove the track from the machine 1.

2.

3.

Remove the track from the machine.

231002469

1

231002470

2

231002470

3

Slide the track tension assembly (2) out of the main frame (1).

Slide the yoke assembly (2) off of the track tension assembly (1).

84522361 15/06/2011

D.50.B / 10

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

Track tensioning mechanism - Install C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

Slide the yoke assembly (2) onto the track tension assembly (1).

231002471

1

231002470

2

Slide the track tension assembly (2) into the main frame (1).

Next operation: Refer to Rubber track - Install (D.50.B) and install the track. After the track has been installed, follow the procedure Rubber track - Tension adjust (D.50.B) and adjust the tension of the track.

84522361 15/06/2011

D.50.B / 11

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

Track adjustment mechanism - Adjust C227, C232, C238

1.

2.

3.

Make sure all paint is removed from contact surface on end cap and shaft.

23112927

1

23112928

2

23112929

3

23112930

4

Inspect inside edge at all roller locations for any excess paint or rough edges. Remove as required.

Add one Keeper to each end of the rear idler. Two Keepers total are required.

84522361 15/06/2011

D.50.B / 12

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

4.

5.

6.

Start both bolts, but do not tighten.

23112931

5

23112932

6

23112933

7

23112934

8

Insert one shim (1) on each end of the rear idler (2). A total of two shims are needed, the arrows show there location. Be sure to add medium strength thread locker (3)

Move Idler as far back in holes as possible and tighten bolts.

84522361 15/06/2011

D.50.B / 13

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

7.

Make sure the idler end cap ears are not pinched by track frame after bolts are tight.

23112935

8.

Install roller with out bolts and push roller against inside track frame wall.

9.

Use shim as guide to determine the required number of shims needed to fill gap between the roller and the track frame wall.

10.

Maximum of one shim on each end of the roller.

11.

If only one shim is required, install between roller and the outside track frame wall.

12.

Install shim as shown

13.

9

23112937

10

23112938

11

Install bolts in roller, but do not tighten. Repeat shim procedure for all three rollers, then add medium strength thread lock, before tightening all of the bolts.

84522361 15/06/2011

D.50.B / 14

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

14.

Spin all rollers by hand.

23112939

12

23112940

13

NOTE: Rollers should spin easily by hand, using only your palm to grip the roller.

If a roller does not spin freely 15.

Remove edge of track frame wall for 2 inches on each side of roller hole.

16.

Install roller and confirm roller spins freely.

84522361 15/06/2011

D.50.B / 15

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

Roller - Remove C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Prior operation: Refer to Rubber track - Remove (D.50.B) and remove the track from the machine. NOTE: Photos are for reference only. Photo shows track installed on the machine. 1.

2.

After the track has been removed from the machine, loosen and remove the cap screws and washers (1) from the roller (2). Remove the roller (2) from the track assembly.

231002476

1

231002476

2

Repeat the procedure above and remove the remaining rollers (1) from the track assembly.

84522361 15/06/2011

D.50.B / 16

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

Roller - Install C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

NOTE: Photos are for reference only. Photo shows track installed on the machine. NOTE: Apply Locktite 243 to the threads of the roller mounting bolts prior to installation. 1.

2.

Install the roller (2) into the mounting location in the track frame. Install the cap screw (1) and washer into the track frame and through the roller pilot hole. Tighten the mounting bolt (1) to a torque of 336 - 371 Nm. (248 - 274 lb ft)

231002476

1

231002476

2

Install the remaining rollers in the track frame mounting locations. Install the cap screw and washer into the track frame and through the roller pilot hole. Tighten the mounting bolt to a torque of 336 - 371 Nm. (248 - 274 lb ft)

Next operation: Refer to Rubber track - Install (D.50.B) and install the track. After the track has been installed, follow the procedure Rubber track - Tension adjust (D.50.B) and adjust the tension of the track.

84522361 15/06/2011

D.50.B / 17

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

Idler wheel - Remove C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Prior operation: Refer to Rubber Track - Rubber track - Remove (D.50.B) and remove the track from the machine. 1.

2.

3.

Front Idler Wheel: Remove the track from the machine. Slide the track tension assembly (2) out of the main frame (1).

231002470

1

231002471

2

231002472

3

Loosen and remove the mounting screw (1) in the yoke (2) which fastens the front idler wheel (3) to the yoke (2). Remove the front idler wheel (3) from the yoke (2).

Rear Idler Wheel: Loosen and remove the cap screw (1) and washer from the rear idler wheel (2). Remove the rear idler wheel (2) from the main frame (3).

84522361 15/06/2011

D.50.B / 18

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Tracks

Idler wheel - Install C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

NOTE: Apply LOCTITE® 243 to the threads of the front and rear idler wheel mounting bolts prior to installation. 1.

2.

3.

Front Idler Wheel: Install the front idler wheel (3) into the yoke (2). Install the screw into the yoke and into the front idler wheel. Tighten the screw (1) to a torque of 183 - 205 Nm (136 - 153 lb ft)

231002471

1

231002470

2

231002472

3

Slide the track tension assembly (2) into the main frame (1).

Rear Idler Wheel: Install the rear idler wheel (2) into the main frame (3). Install the screw (1) into the main frame and into the rear idler wheel (2). Tighten the screw (1)to a torque of 555 - 620 Nm (406 - 460 lb ft).

Next operation: Refer to Rubber track - Install (D.50.B) and install the track. After the track has been installed, follow the procedure - Rubber track - Tension adjust (D.50.B) and adjust the tension of the track.

84522361 15/06/2011

D.50.B / 19

Index AXLES, BRAKES AND STEERING - D WHEELS AND TRACKS Tracks - 50.B Drive sprocket - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Drive sprocket - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Idler wheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Idler wheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Roller - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Roller - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Rubber track - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Rubber track - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Rubber track - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Track adjustment mechanism - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C227, C232, C238

Track tensioning mechanism - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Track tensioning mechanism - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

84522361 15/06/2011

D.50.B / 20

AXLES, BRAKES AND STEERING - D WHEELS AND TRACKS Wheels - 50.C

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

D.50.C / 1

Contents AXLES, BRAKES AND STEERING - D WHEELS AND TRACKS Wheels - 50.C

SERVICE WHEELS AND TRACKS Wheels Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

D.50.C / 2

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Wheels

WHEELS AND TRACKS Wheels - Service instruction WARNING Explosion hazard! Always maintain correct tire pressure as indicated in this manual. DO NOT inflate tires above the recommended pressure. Excessive pressure could result in tire failure. Failure to comply could result in death or serious injury. W0109A

WARNING Explosion hazard! Tires must be replaced by skilled personnel with the proper tools and technical knowledge. Unskilled personnel replacing wheels or tires could result in serious physical injuries, tire damage, and/or wheel distortion. Always have a qualified tire mechanic service wheels and tires. Failure to comply could result in death or serious injury. W0171A

1.

The skid steer will be hard to turn and the tires will wear faster if the correct pressure is not maintained. When a worn or damaged tire is replaced, the replacement must be the same size and tread design as the other tires on the machine. Two different sized tires on one side of the machine will cause accelerated tire wear, loss of power, and excessive strain on the drivetrain. Replace worn tires in pairs with the two new tires used on the same side of the loader. If this tilts the loader too much, replace all four tires.

Adding air to the tires NOTICE: Tire pressure gauges should be checked at regular intervals for calibration and accuracy. TIRE XD2002 XD2002 Beefy Baby II Beefy Baby II Hulk Hulk Bulky Hulk King Kong King Kong Hippo Hippo

SIZE 10x16.5 12x16.5 10x16.5 12x16.5 10x16.5 12x16.5 33/15.5x16.5 10x16.5 12x16.5 31/15.5x16.5 33/15.5x16.5

PRESSURE 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi 40 - 60 psi

84522361 15/06/2011

D.50.C / 3

AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Wheels

Wheel torque Wheel taper nut torque Flange nut

169.5 N·m (125 lb ft) 203.5 N·m (150 lb ft)

This procedure is only for adding air to the tire. If the tire has lost most or all of the air, do the following. 1.

Before you add air, have the wheel correctly installed on the machine or put the wheel in a restraining device (tire inflation cage).

2.

Use an air hose with a remote shutoff valve, selflocking air chuck and wear eye protection.

3.

Stand BEHIND the tread of the tire and make sure ALL persons are away from the side of the tire before you start to add air.

4.

Inflate the tire to the recommended air pressure. DO NOT inflate the tire more than the recommended maximum pressure given on the tire.

84522361 15/06/2011

D.50.C / 4

Index AXLES, BRAKES AND STEERING - D WHEELS AND TRACKS Wheels - 50.C WHEELS AND TRACKS Wheels - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

D.50.C / 5

New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

84522361 15/06/2011 EN

SERVICE MANUAL FRAME AND CAB

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

E

Contents FRAME AND CAB - E

FRAME Primary frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.10.B C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.20.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

USER CONTROLS AND SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

USER CONTROLS AND SEAT Operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.C C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

USER PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.34.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

ENVIRONMENT CONTROL Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.40.C C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

SAFETY SECURITY ACCESSORIES Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.50.B C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

E

FRAME AND CAB - E FRAME Primary frame - 10.B

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

E.10.B / 1

Contents FRAME AND CAB - E FRAME Primary frame - 10.B

FUNCTIONAL DATA FRAME Primary frame Overview Model Frame Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

E.10.B / 2

FRAME AND CAB - FRAME Primary frame

FRAME Primary frame - Overview Model Frame Identification Model

Frame Size Small Radial boom architecture

Engine ISM 34 kW (46.2 Hp)

L215

Small Radial boom architecture

ISM 39 kW (53.0 Hp)

L218

Medium Vertical boom architecture

ISM 45 kW (61.2 Hp)

L220

Medium Vertical boom architecture

ISM 45 kW (61.2 Hp)

L223

Large Vertical boom architecture

F5C 55 kW (74.8 Hp)

L225

Large Vertical boom architecture

F5C 61 kW (82.9 Hp)

L230

Large Vertical boom architecture

F5C 67 kW (91.1 Hp)

C227

Medium Radial boom architecture

F5C 55 kW (74.8 Hp)

C232

Large Vertical boom architecture

F5C 61 kW (82.9 Hp)

C238

Large Vertical boom architecture

F5C 67 kW (91.1 Hp)

L213

84522361 15/06/2011

E.10.B / 3

Index FRAME AND CAB - E FRAME Primary frame - 10.B FRAME Primary frame - Overview Model Frame Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

E.10.B / 4

FRAME AND CAB - E SHIELD - 20.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

E.20.A / 1

Contents FRAME AND CAB - E SHIELD - 20.A

SERVICE Engine hood Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84522361 15/06/2011

E.20.A / 2

FRAME AND CAB - SHIELD

Engine hood - Remove 1.

2.

3.

4.

Remove fuel lines (1) from support strap.

931001670

1

931001668

2

931001672

3

931001675

4

Remove hardware (2) from filter base and remove from door

Disconnect back up alarm electrical connections (3).

If applicable, disconnect rear light electrical connections (4).

84522361 15/06/2011

E.20.A / 3

FRAME AND CAB - SHIELD

5.

6.

Remove door hardware (5).

931001676

5

931001678

6

Remove rear door and grill assembly (6).

84522361 15/06/2011

E.20.A / 4

FRAME AND CAB - SHIELD

Engine hood - Install 1.

2.

3.

4.

Install rear access door and grill assembly in mounts

931001678

1

931001676

2

931001673

3

931001671

4

Install door hardware, bolt (1) and nut (2) to the upper and lower mounts.

Connect back up alarm electrical connection (3).

Mount fuel filter base to door using bolts (B) and nuts (A).

84522361 15/06/2011

E.20.A / 5

FRAME AND CAB - SHIELD

5.

Support the fuel lines (5) to the back door using wire ties (4).

931001670

84522361 15/06/2011

E.20.A / 6

5

Index FRAME AND CAB - E SHIELD - 20.A Engine hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

E.20.A / 7

84522361 15/06/2011

E.20.A / 8

FRAME AND CAB - E USER CONTROLS AND SEAT - 32.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

E.32.A / 1

Contents FRAME AND CAB - E USER CONTROLS AND SEAT - 32.A

SERVICE Console Left - Remove Left hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Left - Install Left hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Instrument panel Digital instrument cluster - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Digital instrument cluster - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove Right hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Instrument panel - Install Right hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

84522361 15/06/2011

E.32.A / 2

FRAME AND CAB - USER CONTROLS AND SEAT

Console Left - Remove Left hand side console 1.

Locate the left hand console (1), inside operator's cab front left side cab frame post

93107448A

84522361 15/06/2011

E.32.A / 3

1

FRAME AND CAB - USER CONTROLS AND SEAT

2.

3.

4.

Remove left console mounting hardware (1).

93109327Z

2

20111506

3

Remove connector from the switch (1).

Unclip the switch from the console.

84522361 15/06/2011

E.32.A / 4

FRAME AND CAB - USER CONTROLS AND SEAT

Console Left - Install Left hand side console 1.

2.

Insert switch into console. Connect the connector to the switch (1).

20111506

1

93109327Z

2

Insert the mounting hardware into the left side (1) and right side of the console (2).

84522361 15/06/2011

E.32.A / 5

FRAME AND CAB - USER CONTROLS AND SEAT

Instrument panel Digital instrument cluster - Remove 1.

2.

Locate instrument cluster (1) on the right hand frame post inside operator's cab.

93107444

1

93109330

2

Remove hardware (1) retaining the instrument cluster on to the right hand frame post.

84522361 15/06/2011

E.32.A / 6

FRAME AND CAB - USER CONTROLS AND SEAT

3.

Disconnect connector X-C23 from the instrument cluster (1).

93105890B

84522361 15/06/2011

E.32.A / 7

3

FRAME AND CAB - USER CONTROLS AND SEAT

Instrument panel Digital instrument cluster - Install Prior operation: Instrument panel Digital instrument cluster - Remove (E.32.A) 1.

2.

Connect connector X-C23 to the instrument cluster (1).

93105890B

1

93109330

2

Place instrument cluster (1) into right hand frame post. Place hardware (2) into instrument cluster to secure to frame post.

84522361 15/06/2011

E.32.A / 8

FRAME AND CAB - USER CONTROLS AND SEAT

Instrument panel - Remove Right hand side console 1.

2.

Locate instrument cluster (1) on the right hand frame post inside operator's cab.

93107444

1

93109330

2

Remove the mounting hardware from the left side (1) and right side (2) of the right hand console.

84522361 15/06/2011

E.32.A / 9

FRAME AND CAB - USER CONTROLS AND SEAT

3.

Disconnect connector from the switch. switch from the right hand console (1).

Remove

20111505

84522361 15/06/2011

E.32.A / 10

3

FRAME AND CAB - USER CONTROLS AND SEAT

Instrument panel - Install Right hand side console 1.

2.

Insert switch into the right hand console (1). Connect the connector to the switch.

20111505

1

93109330

2

Insert the mounting hardware into the left side (1) and right side (2) of the right hand console. Tighten to proper torque.

84522361 15/06/2011

E.32.A / 11

Index FRAME AND CAB - E USER CONTROLS AND SEAT - 32.A Console Left - Install Left hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Console Left - Remove Left hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Instrument panel - Install Right hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Instrument panel - Remove Right hand side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Instrument panel Digital instrument cluster - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Instrument panel Digital instrument cluster - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84522361 15/06/2011

E.32.A / 12

FRAME AND CAB - E USER CONTROLS AND SEAT Operator seat - 32.C

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

E.32.C / 1

Contents FRAME AND CAB - E USER CONTROLS AND SEAT Operator seat - 32.C

DIAGNOSTIC Command Testing Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Testing Operator Restraint Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Heater Testing Seat Heat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84522361 15/06/2011

E.32.C / 2

FRAME AND CAB - USER CONTROLS AND SEAT Operator seat

Command - Testing Seat Switch NOTE: Use schematics Wiring harness - Electrical schematic frame 03 (A.30.A) Wiring harness - Electrical schematic frame 20 (A.30.A) NOTE: The seat switch may become misaligned and not function properly, due to switch mounting or seat cushion compression. Ensure proper switch mounting before replacing switch. Test Point N° 1 Condition Disconnect connector X-58 from connector X-58A. Connect a jumper between connector X-58 pins 3 and 4. Check for circuit operation. 2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-C23 pin 3 and connector X-58 pin 3. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-C23 pin 12 and connector X-58 pin 4. 4 Condition Use Data bus - General specification Instrument Cluster pin information (A.50.A) to Check INSTRUMENT CLUSTER pins 3 and 12.

Expected Result Result No circuit problems. Action The SEAT SWITCH S-002 or connecting wiring has failed. Replace the switch or failed wiring.

Other Result (Possible Cause) Result No change in circuit response, remove jumper. Action Go to test 2

Result No wire problems. Action Go to test 3

Result Wire problems are found. Action Locate and repair or replace broken wire 315/317/313 (Red) or adjacent wiring.

Result No wire problems. Action Go to test 4

Result Wire problems are found. Action Locate and repair or replace broken wire 323/328 (Yellow) (EH) 323 (Yellow) (Mech) or adjacent wiring.

Result No resistance problems. Action The SEAT SWITCH S-002 or connecting wiring has failed. Replace the switch or failed wiring.

Result Resistance problems are found. Action Replace the INSTRUMENT CLUSTER.

84522361 15/06/2011

E.32.C / 3

FRAME AND CAB - USER CONTROLS AND SEAT Operator seat

Command - Testing Operator Restraint Switch NOTE: Wiring Wiring Wiring

Use schematics harness - Electrical schematic frame 03 (A.30.A) harness - Electrical schematic frame 20 (A.30.A) harness - Electrical schematic frame 26 (A.30.A)

NOTE: For EH machines follow steps 1-5. For Mechanical machines follow steps 6-8. Test Point N° 1 Condition Disconnect connector X-104 from the OPERATOR RESTRAINT SWITCH S-043. Connect a jumper between connector X-104 pins 1 and 2. Check for circuit operation. 2 Condition Disconnect connector X-99 from the EH LAP BAR DIODE V-005. Check the diode using ELECTRICAL POWER SYSTEM - Testing Diode Testing (A.30.A). 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-104 pin 1 and connector X-C23 pin 3. 4 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-99 pin A and connector X-104 pin 2. 5 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-CN4A pin 10 and connector X-99 pin B.

Expected Result Result No circuit problems Action The OPERATOR RESTRAINT SWITCH has failed. Replace the switch.

Other Result (Possible Cause) Action No change in circuit response, remove jumper. Go to test 2

Result Test satisfactory. Action Go to test 3

Result Diode is faulty. Action Replace the diode.

Result No wire problems. Action Go to test 4

Result Wire problems are found. Action Locate and repair or replace broken wire 317/316 (Red) / 313 (Yellow) or adjacent wiring.

Result No wire problems. Action Go to test 5

Result Wire problems are found. Action Locate and repair or replace broken wire 314 (Yellow) or adjacent wiring.

Result No wire problems. Action The fault may be intermittent. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. If no damage is found, continue operation. Result 6 Condition Disconnect connector X-104 from No circuit problems the OPERATOR RESTRAINT SWITCH Action S-011. Connect a jumper between The OPERATOR RESTRAINT SWITCH has failed. Replace the switch. connector X-104 pins 1 and 2. Check for circuit operation.

84522361 15/06/2011

E.32.C / 4

Result Wire problems are found. Action Locate and repair or replace broken wire 524 (Yellow) or adjacent wiring.

Action No change in circuit response, remove jumper. Go to test 7

FRAME AND CAB - USER CONTROLS AND SEAT Operator seat

Test Point N° 7 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-104 pin 1 and connector X-C23 pin 3. 8 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-C23 pin 13 and connector X-104 pin 2.

Expected Result Result No wire problems. Action Go to test 8

Other Result (Possible Cause) Result Wire problems are found. Action Locate and repair or replace broken wire 317/316 (Red) / 313 (Yellow) or adjacent wiring.

Result No wire problems. Action The fault may be intermittent. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. If no damage is found, continue operation.

Result Wire problems are found. Action Locate and repair or replace broken wire 314 (Yellow) or adjacent wiring.

84522361 15/06/2011

E.32.C / 5

FRAME AND CAB - USER CONTROLS AND SEAT Operator seat

Heater - Testing Seat Heat Switch NOTE: See schematics Wiring harness - Electrical schematic frame 04 (A.30.A) Wiring harness - Electrical schematic frame 20 (A.30.A) Test Point Expected Result N° Result 1 Condition Place the SEAT HEAT SWITCH to the Bulb comes on. Action on position. The seat heat wiring has developed Check an open, or the SEAT HEAT ELEMENT for indicator bulb illumination. R-001 has failed. Replace the SEAT HEAT ELEMENT or faulty wiring. Result 2 Condition Remove ACCESSORY FUSE from the 0 Ω MAIN POWER DISTRIBUTION FUSE Action Go to test 3 BLOCK 1 Z-2008 Check for continuity across ACCESSORY FUSE. Result 3 Condition With the fuse removed, and ignition 12 V Action on, Go to test 4 Check for voltage from MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C1 and ground. Result 4 Condition Use ELECTRICAL POWER SYS- No wire problems TEM - Testing General Wire Test- Action ing (A.30.A) to check wire condition Go to test 5 between MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C2 and connector X-58 pin 1. 5 Condition Result Use ELECTRICAL POWER SYS- No wire problems. TEM - Testing General Wire Test- Action ing (A.30.A) to check wire condition Go to test 6 between connector X-58 pin 2 and cab ground. Result 6 Condition While cycling the SEAT HEAT Infinite resistance with switch in off position, low resistance with switch SWITCH, in on position. Check resistance between connector X-58 Action The seat heat wiring has developed pin 1 and connector X-58 pin 2. an open, or the SEAT HEAT ELEMENT R-001 has failed. Replace the SEAT HEAT ELEMENT or faulty wiring.

84522361 15/06/2011

E.32.C / 6

Other Result (Possible Cause) Result Bulb does not light. Action Go to test 2

Result Fuse is blown. Action Replace the fuse with same type and amp rating. Result 0V Action There is a problem in the DC distribution system upstream of ACCESSORY FUSE Result Wire problems are found. Action Locate and repair or replace broken wire 134/152/756 (Orange) or adjacent wiring. Result Wire problems are found. Action Locate and repair or replace broken wire 933/1088/1093 (Black) or adjacent wiring. Result Open in both positions. Action The SEAT HEAT SWITCH S-003 has failed. Replace the switch.

Index FRAME AND CAB - E USER CONTROLS AND SEAT Operator seat - 32.C Command - Testing Operator Restraint Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Command - Testing Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Heater - Testing Seat Heat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84522361 15/06/2011

E.32.C / 7

84522361 15/06/2011

E.32.C / 8

FRAME AND CAB - E USER PLATFORM - 34.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

E.34.A / 1

Contents FRAME AND CAB - E USER PLATFORM - 34.A

FUNCTIONAL DATA Door, window and windscreen Overview Door Switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Tilt system Tilt To secure the lift arm in the raised position on radial lift machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DIAGNOSTIC Cigar lighter Testing Accessory Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Door, window and windscreen Testing Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

84522361 15/06/2011

E.34.A / 2

FRAME AND CAB - USER PLATFORM

Door, window and windscreen - Overview Door Switch - Overview If a unit has a door, the Door Switch Function will prevent the operator from operating the loader arm and bucket while the door is open. This will prevent damage to the machine because when the door is open it is directly in the path of the implement. The operator can open the door at any time and the joystick control of loader and bucket will be shut off over software and the port locks will engage. Once the door is closed the operator will regain control of the attachment. The Door Switch is a magnetic reed switch. The switch operates on low current, and closes in the presence of metal. The switch mush be adjusted properly to function correctly. The Door Switch Function is active when Ignition is ON.

84522361 15/06/2011

E.34.A / 3

FRAME AND CAB - USER PLATFORM

Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. DANGER Crushing hazard! Loader lift arm is unsupported during support strut removal. Do not enter or exit the operator's compartment with an unsupported loader lift arm. Two persons are required during storage. One person should remove and store the support strut while the operator remains in the operator's compartment. Failure to comply will result in death or serious injury. D0021A

WARNING Crushing hazard! If you service the machine with the loader lift arms raised, always use the support strut. Remove the retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support strut. Lower the lift arms onto the support strut. Failure to comply could result in death or serious injury. W0230A

1.

Remove any attachment.

2.

Park the machine on firm and level surface.

3.

See the instructional decal on the inside of the right lift arm, just above the support strut. Read and understand these instructions before you perform this procedure.

4.

Remove the retaining clip (1) that secures the lift arm support strut.

5.

Lay the support (1) down on the lift arm tubing and cylinder, as shown.

6.

Slowly raise the lift arms until the support strut drops down onto the cylinder, as shown.

7.

Install retaining clip (2) to secure support strut to the lift arm cylinder. Gently, lower the lift arms down until the support strut is in contact with the cylinder.

84522361 15/06/2011

E.34.A / 4

93106848A

1

93106854A

2

FRAME AND CAB - USER PLATFORM

To secure the lift arms up and install the support lock pin on vertical lift machines. DANGER Crushing hazard! Failure to engage the loader arm support pin could cause the loader arm to fall unexpectedly. Verify that the loader arm support pin is engaged. Failure to comply will result in death or serious injury. D0020A

1.

Remove any attachment.

2.

Park machine on firm level surface.

3.

See instructional decal (2) located by the lift arm lever lock.

4.

Raise the loader arm until loader link is above the lock pins.

5.

Rotating mechanical lift arm lock lever (1) towards the inside of the machine will extend the pins and the lift arms will be LOCKED.

6.

Slowly lower lift arm until it rests on the lock pins.

93109334

84522361 15/06/2011

E.34.A / 5

3

FRAME AND CAB - USER PLATFORM

Move operator protective structure to service position. 1.

The operators compartment may be tilted forward, for service access, only with the lift arms raised. Following instruction provided to access the engine, hydrostatic pumps, motors and control linkage.

2.

To tilt the cab, confirm that the following steps have been completed.

3.

The machine is on firm, level ground.

4.

The lift arms are up with the support strut or lock pin in lock position.

5.

Use a 24 mm (15/16 in) socket or wrench to remove the two rear ROPS retaining nuts (1).

6.

Use the cab entry hand holds and pivot the cab forward as shown.

7.

Confirm red lock tube (1) has lowered over pivot linkage.

84522361 15/06/2011

E.34.A / 6

93107498

4

93105463

5

93107499A

6

FRAME AND CAB - USER PLATFORM

Tilt system - Lower DANGER Crushing hazard! Loader lift arm is unsupported during support strut removal. Do not enter or exit the operator's compartment with an unsupported loader lift arm. Two persons are required during storage. One person should remove and store the support strut while the operator remains in the operator's compartment. Failure to comply will result in death or serious injury. D0021A

WARNING Crushing hazard! If you service the machine with the loader lift arms raised, always use the support strut. Remove the retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support strut. Lower the lift arms onto the support strut. Failure to comply could result in death or serious injury. W0230A

To lower the cab 1.

To place the cab and loader lift arms back into the work position raise the red lock tube over the cab pivot linkage.

2.

Confirm red lock tube (1) is raised over pivot linkage.

3.

Use the cab entry hand holds and pivot the cab down onto frame.

4.

Use a 24mm socket or wrench to install the two rear ROPS retaining nuts (1) to a torque of 170 N·m (125.4 lb ft) .

84522361 15/06/2011

E.34.A / 7

93107499A

1

931001633

2

FRAME AND CAB - USER PLATFORM

To lower the working arms and disengage the support lock pin on vertical lift machines. DANGER Crushing hazard! Failure to engage the loader arm support pin could cause the loader arm to fall unexpectedly. Verify that the loader arm support pin is engaged. Failure to comply will result in death or serious injury. D0020A

1.

While sitting in the operator's seat with the seat belt fastened and the engine running, Raise the lift arm (4) high enough to clear the lift arm lock pins (3). Rotate the mechanical lift arm lock lever away from the seat (counter - clockwise) to retract the lock pins.

NOTICE: See the instructional decal (2) located by the mechanical lift arm lock lever. 2.

Slowly lower the lift arm until the lift arms are on the ground or floor.

84522361 15/06/2011

E.34.A / 8

93107457

3

93109334

4

FRAME AND CAB - USER PLATFORM

To lower the working arms and disengage the support bracket on radial lift machines. WARNING Crushing hazard! If you service the machine with the loader lift arms raised, always use the support strut. Remove the retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support strut. Lower the lift arms onto the support strut. Failure to comply could result in death or serious injury. W0230A

DANGER Crushing hazard! Loader lift arm is unsupported during support strut removal. Do not enter or exit the operator's compartment with an unsupported loader lift arm. Two persons are required during storage. One person should remove and store the support strut while the operator remains in the operator's compartment. Failure to comply will result in death or serious injury. D0021A

1.

See the instructional decal on the inside of the right lift arm, just above the support strut. Read and understand these instructions before you perform this procedure.

NOTE: Two people are required for this procedure. 2.

One person should remove retaining clip (1) from support strut while the operator remains in the operator's compartment.

3.

Slowly raise the lift arms until the support strut separates from the cylinder.

4.

Have the person outside the unit raise support strut and secure through tab with retaining clip (1), as shown.

5.

Once the second person has cleared the area, the working arm can be lowered.

84522361 15/06/2011

E.34.A / 9

93106854A

5

93106848A

6

FRAME AND CAB - USER PLATFORM

Cigar lighter - Testing Accessory Power Outlet NOTE: Use schematics Wiring harness - Electrical schematic frame 04 (A.30.A) Wiring harness - Electrical schematic frame 06 (A.30.A) Test Point N° 1 Condition Remove ACCESSORY / BEACON FUSE from the MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008. Check for continuity across ACCESSORY / BEACON FUSE. 2 Condition With the fuse removed and Ignition on, Check for voltage from MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin D5 and ground. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-ACC pin B and MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin D6. 4 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-ACC pin A and ground.

Expected Result Result 0Ω Action Go to test 2

Other Result (Possible Cause) Result Fuse is blown. Action Replace the fuse with same type and amp rating.

Result 12 V Action Go to test 3

Result 0V Action There is a problem in the DC distribution system upstream of ACCESSORY / BEACON FUSE.

Result No wire problems. Action Go to test 4

Result Wire problems are found. Action Locate and repair or replace broken wire 801/115/196 (Red) or adjacent wiring.

Result No wire problems. Action The ACCESSORY POWER OUTLET Z-008 has failed. Replace the ACCESSORY POWER OUTLET.

Result Wire problems are found. Action Locate and repair or replace broken wire 952/842/1094 (Black) or adjacent wiring.

84522361 15/06/2011

E.34.A / 10

FRAME AND CAB - USER PLATFORM

Door, window and windscreen - Testing Door Switch NOTE: Use schematics Wiring harness - Electrical schematic frame 03 (A.30.A) Wiring harness - Electrical schematic frame 09 (A.30.A) Test Point N° 1 Condition Disconnect connector X-505 from the DOOR SWITCH. Connect a jumper between connector X-505 pins 1 and 2. Check Check circuit operation. 2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-505 pin 2 and ground. 3 Condition Disconnect connector X-502 from the DOOR WIPER MOTOR. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-505 pin 1 and connector X-C23 pin 17. 4 Condition Use Data bus - General specification Instrument Cluster pin information (A.50.A) to Check INSTRUMENT CLUSTER pin 17.

Expected Result Other Result (Possible Cause) Result Result No change in circuit response, reNo circuit problems. move jumper. Action The DOOR SWITCH has failed. Re- Action Go to test 2 place the switch.

Result No wire problems. Action Go to test 3

Result Wire problems are found. Action Repair or replace broken wire 1016/ 910/966 (Black).

Result No wire problems. Action Go to test 4

Result Wire problems are found. Action Repair or replace broken wire 250/ 251 (Yellow) or wire 220 (Yellow).

Result No resistance problems. Action The fault may be intermittent. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. If no damage is found, continue operation.

Result Resistance problems are found. Action Replace the INSTRUMENT CLUSTER.

84522361 15/06/2011

E.34.A / 11

Index FRAME AND CAB - E USER PLATFORM - 34.A Cigar lighter - Testing Accessory Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Door, window and windscreen - Overview Door Switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Door, window and windscreen - Testing Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tilt system - Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. . . . . . . . . . . . . . . . . . . . . . . . . . 4

84522361 15/06/2011

E.34.A / 12

FRAME AND CAB - E ENVIRONMENT CONTROL Air-conditioning system - 40.C

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

E.40.C / 1

Contents FRAME AND CAB - E ENVIRONMENT CONTROL Air-conditioning system - 40.C

FUNCTIONAL DATA ENVIRONMENT CONTROL Air-conditioning system Overview HVAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview HVAC Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview HVAC Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electronic A/C control Overview HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE ENVIRONMENT CONTROL Air-conditioning system ENVIRONMENT CONTROL Air-conditioning system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

DIAGNOSTIC ENVIRONMENT CONTROL Air-conditioning system Problem solving HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Compressor Testing A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Condenser Testing HVAC Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Electronic A/C control Testing Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Testing A/C Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Testing HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Testing HVAC Heat Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Sensing system Testing HVAC High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

84522361 15/06/2011

E.40.C / 2

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC System NOTE: For more information on the mechanical operation of the HVAC system see: ENVIRONMENT CONTROL Airconditioning system - Overview HVAC Mechanical (E.40.C) and for more information on the electrical operation of the HVAC system see: ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical (E.40.C). The function of the HVAC system is to improve the operator's comfort by conditioning the air inside the cab. In AC mode, temperature control is achieved by absorbing the heat within the cab into a refrigerant and then allowing the heat absorbed by the refrigerant to be transferred to the outside air. In heat mode, temperature control is achieved by air absorbing heat from a heat exchanger (heater core). The BLOWER SWITCH S-020 can provide 4 speed levels (off, low, medium, high) to the Electric Fan Motor (2) (internal to HVAC Box). Low and medium speeds are provided through a Resistor (internal to HVAC Box). The fan blows a mix of outside and cab air (1) across an evaporator (3) and across the heater core (4), providing conditioned air entering the cab through vents (5), and is energized anytime the ignition is on.

ACPATHSL57

1

HVAC air flow path In AC mode, with the AC SWITCH S-017 on, and an Electric Fan speed selected, the HVAC CONDENSER FAN and A/C COMP are energized, starting the refrigeration cycle and providing cool air to the cab. In heat mode, with AC Switch off and the TEMPCONTROL Z-017 potentiometer to “hot”, the potentiometer provides a control signal to the WATER VALVE Z-019 which directs hot engine coolant to flow to the heater core. The Electric Fan Motor (internal to HVAC Box) blows air across the evaporator (not in use) and hot heater core, providing hot air to cab. If both AC switch is on and Tempcontrol potentiometer is turned to "hot", both the Water Valve and AC components are energized, and the air will cool across the Evaporator, then heat across the heater core, then enter the cab. The Blower Switch, AC Switch, and Tempcontrol potentiometer are all located on the Left Console. There are three safety switches in the system that protect the compressor. The Single-Level Pressure Switch (internal to HVAC Box) protects from a liquid lock condition in the refrigeration cycle. The HVAC HIGH PRESSURE SWITCH protects against an overpressure condition caused by a system blockage or compressor failure. The Thermostat (internal to HVAC Box) is a freeze sensor, located on the condenser, that cycles the A/C COMPRESSOR off preventing an ice over condition, which would prevent heat transfer.

84522361 15/06/2011

E.40.C / 3

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Mechanical The principal components of an air conditioning system are •

Refrigerant

•

Evaporator

•

Compressor

•

Condenser

•

Expansion Valve

To achieve the absorption and the release of heat, which is, in essence, the function of an air conditioning system, requires the use of a suitable refrigerant, a liquid that has a relatively low temperature boiling point, plus certain desirable safety and stability features. The refrigerant used in the air conditioning system is R-134a. The refrigerant starts as a low temperature, low pressure liquid and enters the evaporator. The evaporator (1) consists of a number of turns of continuous coils mounted in a series of thin cooling fins to provide a maximum heat transfer area in a minimum amount of space. Low temperature refrigerant in the evaporator absorbs heat from the hotter air in the cab, cooling the air. The Electric Fan Motor (internal to HVAC Box) blows a mix of outside air and recirculated cab air across the evaporator and blows this cool air into the cab. The refrigerant now changes to a high temperature, low pressure vapor and leaves the evaporator, moving to the suction (low pressure) side of the compressor.

REFCYCLESL57

1

Refrigeration Cycle The compressor (2) acts as a pump which raises the refrigerant temperature and pressure by compression to a higher degree of temperature than the ambient (outside air) temperature and provides the driving force required to circulate the volume of refrigerant through the system. Refrigerant is drawn into the compressor as a high temperature, low pressure vapor which is compressed and then pumped out as a high temperature, high pressure vapor to the condenser. The Thermostat (internal to HVAC Box) cycles power to the A/C COMPRESSOR via removing power to compressor relay control. The condenser (3) consists of a number of turns of continuous coil mounted in a series of thin cooling fins to provide a maximum of heat transfer in a minimum area of space. The condenser receives the high temperature, high pressure refrigerant vapor from the compressor. The hot vapor passes through the condenser coils and outside air is pushed across the condenser by the HVAC CONDENSER FAN. Heat moves from the hot refrigerant vapor into the cooler outside air flowing across the condenser coils and fins. When the refrigerant vapor reaches the pressure and temperature that will induce a change of state to a liquid, a large quantity of heat is transferred to the outside air and the refrigerant changes to a low temperature, high pressure liquid. The refrigerant from the condenser enters the expansion valve (4) as a low temperature, high pressure liquid. The expansion valve allows the refrigerant to expand rapidly, which causes the pressure and temperature of the refrigerant to be reduced and the refrigerant leaves the expansion valve as a low temperature, low pressure liquid.

84522361 15/06/2011

E.40.C / 4

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical NOTE: See schematic Wiring harness - Electrical schematic frame 17 (A.30.A) The HVAC system has several power inputs. One line of source power comes from the ACCESSORY RELAY K-018 to the HVAC BOX A-003 on pin 11. This energizes the Auxiliary Relay for Electric Fan coil (internal to HVAC Box). The Accessory Relay is powered from the INSTRUMENT CLUSTER when the ignition is on, which shuts the Auxiliary Relay for Electric Fan. NOTE: See HVAC Box overview for more information Electronic A/C control - Overview HVAC Box (E.40.C) The Auxiliary Relay for Electric Fan main power comes directly from the BATTERY via HVAC FUSE F-001 through HVAC Box pin 14. The Auxiliary Relay for Electric Fan is shut anytime the ignition is on, allowing power to WATER VALVE Z-019 and TEMPCONTROL Z-017 potentiometer, also allowing power to BLOWER SWITCH S-020 from HVAC Box pin 10. Power is provided to the AC SWITCH S-017, from the Blower Switch, anytime a fan speed is selected. The Blower Switch, AC Switch, and Tempcontrol potentiometer are all located on the Left Console. Since the Water Valve and Tempcontrol are energized, cab heat is available anytime the ignition is on. When the AC Switch is turned “on” and an Electric Fan speed is selected, power is provided to HVAC Box pin 6, through Single-Level Pressure Switch (internal to HVAC Box), through Thermostat (internal to HVAC Box), out HVAC Box pin 7 to HVAC HIGH PRESSURE SWITCH back into HVAC Box pin 8 to the Compressor Relay coil (internal to HVAC Box), shutting the Compressor Relay (internal to HVAC Box). When Compressor Relay is shut, this allows battery power via COMPRESSOR FUSE F-002 through HVAC Box pin 2 to the Compressor Relay, out HVAC box pin 12, to the A/C COMP. When the AC Switch is turned “on” and an Electric Fan speed is selected, power is also applied to the CONDENSER RELAY coil, shutting the Condenser Relay, providing battery power via fuse F-002 to the CONDENSER FAN. The Blower Switch, since energized, can provide 4 speed levels (off, low, medium, high) through HVAC box pins 3, 4, and 5 (low, medium, and high) to the Electric Fan Motor (internal to HVAC Box). This is done through a Resistor (internal to HVAC Box).

84522361 15/06/2011

E.40.C / 5

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

Electronic A/C control - Overview HVAC Box NOTE: See X-HVC1 and X-HVC2 for connector information NOTE: See ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical (E.40.C)for electrical flowpath description. Components in HVAC BOX A-003 Designation (1) (2) (3) (4) (5) (6) (7)

Component Compressor Relay Auxiliary Relay for Electric Fan Resistor Electric Fan Motor No-Frost Electronic Thermostat Single-Level Pressure Switch Connector X-HVC2

HVACBOXSCHEMSL5

1

HVAC BOX A-003 Schematic HVAC Box Pin Information (numbered from top to bottom on schematic) Pin Number 3 4 5 2 10

Wire Description Power to Low Speed portion of Resistor from BLOWER SWITCH S-020 Power to Medium Speed portion of Resistor from BLOWER SWITCH S-020 High Speed power to Electric Fan Motor from BLOWER SWITCH S-020 Power to Compressor Relay from COMPRESSOR FUSE F-002 Power to BLOWER SWITCH S-020, TEMPCONTROL Z-017 potentiometer, and WATER VALVE Z-019 from Auxiliary Relay for Electric Fan

84522361 15/06/2011

E.40.C / 6

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

14 9 12 11 6 1

13 8 7

Power to Auxiliary Relay for Electric Fan from HVAC FUSE F-001 Ground path from Thermostat Power to A/C COMPRESSOR from Compressor Relay Power to Auxiliary Relay for Electric Fan coil from ACCESSORY RELAY K-018 Power to Single-Level Pressure Switch and Thermostat from AC SWITCH S-017 Ground for Compressor Relay coil Ground for Auxiliary Relay for Electric Fan coil Ground for Electric Fan Motor not used Power to Compressor Relay coil from HVAC HIGH PRESSURE SWITCH Power to HVAC HIGH PRESSURE SWITCH from Thermostat

84522361 15/06/2011

E.40.C / 7

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

ENVIRONMENT CONTROL Air-conditioning system - Remove Prior operation: Bucket - Remove (J.20.B) 1.

2.

3.

4.

Disconnect air condition hoses (1) and cap open ports.

931001817

1

931001817

2

931001759

3

931001793

4

Label and disconnect heater hoses (2) and cap open ports.

Remove seat hardware (3).

Disconnect seat safety switch electrical connection (4).

84522361 15/06/2011

E.40.C / 8

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

5.

6.

7.

8.

Remove operators seat.

931001756

5

931001752

6

931001751

7

931001775

8

Remove mounting screws (5) and remove cover (6).

Remove rear panel hardware (7).

Remove window wash bottle lid (8).

84522361 15/06/2011

E.40.C / 9

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

9.

Remove rear panel exposing air conditioning unit.

931001774

10.

11.

12.

9

Remove left hand side and right hand side duct work hardware (9).

931001763

10

931001769

11

931001771

12

Remove air condition unit mounting hardware (10).

Disconnect air condition electrical connector (11).

84522361 15/06/2011

E.40.C / 10

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

13.

Remove air condition unit.

931001773

84522361 15/06/2011

E.40.C / 11

13

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

ENVIRONMENT CONTROL Air-conditioning system - Install Prior operation: Bucket - Remove (J.20.B) 1.

2.

3.

4.

Disconnect air condition hoses (1) and cap open ports.

931001817

1

931001817

2

931001759

3

931001793

4

Label and disconnect heater hoses (2) and cap open ports.

Remove seat hardware (3).

Disconnect seat safety switch electrical connection (4).

84522361 15/06/2011

E.40.C / 12

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

5.

6.

7.

8.

Remove operators seat.

93109313

5

931001752

6

931001751

7

931001775

8

Remove mounting screws (5) and remove cover (6).

Remove rear panel hardware (7).

Remove window wash bottle lid (8).

84522361 15/06/2011

E.40.C / 13

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

9.

Remove rear panel exposing air conditioning unit.

931001774

10.

11.

12.

9

Remove left hand side and right hand side duct work hardware (9).

931001763

10

931001769

11

931001771

12

Remove air condition unit mounting hardware (10).

Disconnect air condition electrical connector (11).

84522361 15/06/2011

E.40.C / 14

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

13.

Remove air condition unit.

931001773

84522361 15/06/2011

E.40.C / 15

13

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

ENVIRONMENT CONTROL Air-conditioning system - Remove Prior operation: Bucket - Remove (J.20.B) 1.

Raise cab to disconnect air conditioning system hoses (1) and cap open ports.

NOTE: If R134A is still in system, it should be drained and captured prior to disconnecting hoses.

2.

931001817

1

931001817

2

931001759

3

931001793

4

Label and disconnect heater hoses (2) and cap open ports.

NOTE: Drain coolant into a suitable container prior to disconnecting heater hoses.

3.

4.

Remove seat hardware (3).

Disconnect seat safety switch electrical connection (4).

84522361 15/06/2011

E.40.C / 16

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

5.

6.

7.

8.

Remove operators seat.

93109313

5

931001752

6

931001751

7

931001775

8

Remove mounting screws (5) and remove cover (6).

Remove rear panel hardware (7).

Remove window wash bottle lid (8).

84522361 15/06/2011

E.40.C / 17

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

9.

Remove rear panel exposing air conditioning unit.

931001774

10.

11.

12.

9

Remove left hand side and right hand side duct work hardware (9).

931001763

10

931001769

11

931001771

12

Remove air condition unit mounting hardware (10).

Disconnect air condition electrical connector (11).

84522361 15/06/2011

E.40.C / 18

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

13.

Remove air condition unit.

931001773

84522361 15/06/2011

E.40.C / 19

13

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

ENVIRONMENT CONTROL Air-conditioning system - Problem solving HVAC OPERATION To understand the electrical flowpaths and help narrow down the troubleshooting efforts, refer to HVAC System Electrical overview ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical (E.40.C). TROUBLESHOOTING Before troubleshooting ensure that 1.

HVAC FUSE F-001 is good.

2.

COMPRESSOR FUSE F-002 is good.

3.

ACCESSORY RELAY K-018 is good. See ELECTRICAL POWER SYSTEM - Component identification Relay Index (A.30.A).

4.

Switches are operated in accordance with Operator's Manual. Problem

Possible Cause Correction Faulty TEMPCONTROL Z-017 potentiometer Electronic A/C control - Testing HVAC Heat Components (E.40.C) Faulty WATER VALVE Z-019 Electronic A/C control - Testing HVAC Heat Components (E.40.C) Faulty Fan Relay (internal to HVAC Box) Electronic A/C control - Testing HVAC Box (E.40.C) Poor Heat Faulty TEMPCONTROL Z-017 potentiometer Electronic A/C control - Testing HVAC Heat Components (E.40.C) Faulty WATER VALVE Z-019 Electronic A/C control - Testing HVAC Heat Components (E.40.C) Poor cooling No voltage at connector X-74 pin B. Faulty CONDENSER RELAY or associated wiring. See Fuse and relay box - Testing Relay Testing (A.50.A) and Fuse and relay box - Testing Condenser Relay Control (A.30.A) Faulty HVAC CONDENSER FAN Condenser - Testing HVAC Condenser Fan (E.40.C) Thermostat (internal to HVAC Box) not cy- Electronic A/C control - Testing HVAC cling correctly Box (E.40.C) Electronic A/C control - Testing HVAC Poor cooling after engine Faulty WATER VALVE Z-019 Heat Components (E.40.C) is at normal temperature Faulty TEMPCONTROL Z-017 potentiometer Electronic A/C control - Testing HVAC Heat Components (E.40.C) No cooling Faulty Fan Relay (internal to HVAC Box) Electronic A/C control - Testing HVAC Box (E.40.C) Faulty BLOWER SWITCH S-020 Electronic A/C control - Testing Blower Switch (E.40.C) Faulty AC SWITCH S-017 Electronic A/C control - Testing A/C Switch (E.40.C) Faulty Single-Level Pressure Switch (inter- Electronic A/C control - Testing HVAC nal to HVAC Box) Box (E.40.C) Faulty Thermostat (internal to HVAC Box) Electronic A/C control - Testing HVAC Box (E.40.C) Faulty HVAC HIGH PRESSURE SWITCH Sensing system - Testing HVAC High Pressure Switch (E.40.C) Faulty Compressor Relay (internal to HVAC Electronic A/C control - Testing HVAC Box) Box (E.40.C) Faulty A/C COMPRESSOR Compressor - Testing A/C Compressor (E.40.C) No fan speeds available No voltage at HVAC Box pin 14 Faulty HVAC FUSE F-001 or associated wiring No heat

84522361 15/06/2011

E.40.C / 20

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

Problem

Possible Cause No voltage at HVAC Box pin 11

Correction Faulty ACCESSORY RELAY K-018 or associated wiring. See Fuse and relay box Testing Relay Testing (A.50.A) and Fuse and relay box - Testing Accessory Relay Control (A.30.A) Faulty BLOWER SWITCH S-020 Electronic A/C control - Testing Blower Switch (E.40.C) Faulty Fan Relay (internal to HVAC Box) Electronic A/C control - Testing HVAC Box (E.40.C) Faulty Electric Fan Motor (internal to HVAC Electronic A/C control - Testing HVAC box) Box (E.40.C) Faulty HVAC Box ground wiring Use ELECTRICAL POWER SYSTEM Testing General Wire Testing (A.30.A) to ensure proper ground from HVAC Box pin 1 Only high speed fan Faulty Resistor (internal to HVAC Box) Electronic A/C control - Testing HVAC available Box (E.40.C) Only one fan speed is not Wiring problem common to HVAC BOX Use ELECTRICAL POWER SYSTEM available A-003 (Resistor) and BLOWER SWITCH Testing General Wire Testing (A.30.A) to locate faulty wire S-020

84522361 15/06/2011

E.40.C / 21

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

Compressor - Testing A/C Compressor NOTE: Use schematics Wiring harness - Electrical schematic frame 17 (A.30.A) Test Point N° 1 Condition With ignition off, use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between A/C COMPRESSOR ground pin and ground. 2 Condition Disconnect connector X-AC_COMP from the A/C COMPRESSOR. With ignition on, Check for voltage from connector X-AC_COMP power pin and ground. 3 Condition With ignition off, use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between A/C COMPRESSOR power pin and X-HVC1 pin 12.

Expected Result Result No wire problems. Action Go to test 2

Other Result (Possible Cause) Result Wire problems are found. Action Locate and repair or replace broken ground wire.

Result 12 V Action The A/C COMPRESSOR has failed. Replace the compressor.

Result 0V Action Go to test 3

Result Wire problems are found. Action Locate and repair or replace broken See the following for further testing wire 841 (White). Result No wire problems. Action

•

ENVIRONMENT CONTROL Air-conditioning system - Problem solving HVAC (E.40.C)

•

Electronic A/C control - Testing HVAC Box (E.40.C)

84522361 15/06/2011

E.40.C / 22

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

Condenser - Testing HVAC Condenser Fan NOTE: Use schematics Wiring harness - Electrical schematic frame 17 (A.30.A) NOTE: Without the Condenser Fan, the Air Conditioning will work poorly. If Air Conditioning does not work at all, see ENVIRONMENT CONTROL Air-conditioning system - Problem solving HVAC (E.40.C) Test Point N° 1 Condition Disconnect connector X-74 from the HVAC CONDENSER FAN. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check ground wire condition between X-74 pin A and ground. 2 Condition With ignition on, Check for voltage from connector X-74 pin B and ground. 3 Condition Disconnect connector X-111 from the CONDENSER RELAY. Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-74 pin B and X-111 pin 87.

Expected Result Result No wire problems. Action Go to test 2

Other Result (Possible Cause) Result Wire problems are found. Action Locate and repair or replace broken wire 1084 (Black).

Result Result 0V 12 V Action Action The HVAC CONDENSER FAN has Go to test 3 failed. Replace the fan. Result Result Wire problems are found. No wire problems. Action Action Locate and repair or replace broken See the following for further testing wire 237 (White). •

Fuse and relay box Testing Condenser Relay Control (A.30.A)

•

ENVIRONMENT CONTROL Air-conditioning system - Problem solving HVAC (E.40.C)

84522361 15/06/2011

E.40.C / 23

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

Electronic A/C control - Testing Blower Switch NOTE: Use schematics Wiring harness - Electrical schematic frame 17 (A.30.A) NOTE: Ensure Electronic A/C control - Testing HVAC Box (E.40.C) test is satisfactory prior to performing this test Test Point N° 1 Condition Disconnect connector X-270 from the BLOWER SWITCH S-020. Check for resistance between BLOWER SWITCH pins 1 and 2 while cycling the Blower Switch. 2 Check for resistance between BLOWER SWITCH pins 2 and 3 (Low) pins 2 and 4 (Medium) pins 2 and 5 (High) while cycling the BLOWER SWITCH. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-HVC1 pin 10 and connector X-270 pin 2.

Expected Result Result 0 Ω when selecting a fan speed, no continuity when fan is selected off. Action Go to test 2

Other Result (Possible Cause) Result Any other readings Action The BLOWER SWITCH has failed. Replace the switch.

Result For each resistance check, 0 Ω in one position, infinite resistance in all others. Action Go to test 3

Result 0 Ω in more than one position or infinite resistance in all positions. Action The BLOWER SWITCH has failed. Replace the switch.

Result Wire problems are found. Action Locate and repair or replace broken See the following for further testing wire 821/846/842 (Orange) or adjaENVIRONMENT CON- cent wiring. • TROL Air-conditioning system - Problem solving HVAC (E.40.C) Result No wire problems. Action

•

Electronic A/C control - Testing HVAC Box (E.40.C)

84522361 15/06/2011

E.40.C / 24

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

Electronic A/C control - Testing A/C Switch NOTE: See schematic Wiring harness - Electrical schematic frame 17 (A.30.A) NOTE: Ensure Electronic A/C control - Testing Blower Switch (E.40.C) test is satisfactory prior to performing this test Test Point N° 1 Condition Use ENVIRONMENT CONTROL Air-conditioning system Overview HVAC System (E.40.C) to set up conditions for the AC system to turn on. Check that AC switch indicator light is on. 2 Condition Disconnect connector X-275 from the AC SWITCH S-017. Use ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC System (E.40.C) to set up conditions for the AC system to turn on. Check for voltage between X-275 pins 1 and ground. 3 Condition Disconnect connector X-275 from the AC SWITCH S-017. Connect a jumper between connector X-275 pins 1 and 2. Check for circuit operation. 4 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-275 pin 2 and connector X-HVC1 pin 6.

Expected Result Result Light on Action Go to test 3

Other Result (Possible Cause) Result Light not on Action Go to test 2

Result 12 V Action Go to test 3

Result 0V Action There is an open on wire 825 (Orange). Repair the wire.

Result No circuit problems. Action The AC SWITCH S-017 has failed. Replace the switch.

Result No change in circuit response. Action Go to test 4

Result Wire problems are found. Action Locate and repair or replace broSee the following for further testing ken wire 829/837 (White) or adjacent ENVIRONMENT CON- wiring. • TROL Air-conditioning system - Problem solving HVAC (E.40.C) Result No wire problems. Action

•

Electronic A/C control - Testing HVAC Box (E.40.C)

84522361 15/06/2011

E.40.C / 25

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

Electronic A/C control - Testing HVAC Box NOTE: Ensure HVAC FUSE F-001 COMPRESSOR FUSE F-002 and ACCESSORY RELAY K-018 are working correctly prior to performing this test. NOTE: Use schematics Wiring harness - Electrical schematic frame 17 (A.30.A) NOTE: See Electronic A/C control - Overview HVAC Box (E.40.C) for additional information Test Point N° 1 Condition Disconnect connector X-HVC2 from X-HVC1. With the ignition on, Check for voltage from connector X-HVC1 pin 2 and ground, 11 and ground, and 14 and ground. 2 Check for resistance between HVAC BOX A-003 pins 1 and 8 and from pins 1 and 11.

3 Check for resistance between HVAC BOX A-003 pins 2 and 12 and from pins 10 and 14.

4 Check for resistance between HVAC BOX A-003 pins 3 and 4 pins 4 and 5 pins 3 and 5. 5 Check for resistance between HVAC BOX A-003 pins 1 and 5

6 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-HVC1 pin 9 and ground. 7 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-HVC1 pin 1 and ground.

Expected Result Result 12 V for each check Action Go to test 2

Other Result (Possible Cause) Result 0V Action There is a problem in the DC distribution system upstream of X-HVC1 pin 2, 11, or 14.

Result Greater than 15 Ω Action Either the Compressor Relay or Fan Relay, both internal to the HVAC Box, has failed. Replace the serviceable component. Result Result Open 0Ω Action Action Go to test 4 Either the Compressor Relay or Fan Relay, both internal to the HVAC Box, has failed. Replace the serviceable component. Result Result The sum of the resistances from pins For any other readings, 3 and 4 and from pins 4 and 5 should Action equal the resistance from pins 3 and The Resistor, internal to the HVAC Box, has failed. Replace the service5. able component. Action Go to test 5 Result Result 10 Ω Either 0 Ω or greater than 1000 Ω Action Action Go to test 6 The Electric Fan Motor, internal to the HVAC Box, has failed. Replace the serviceable component. Result Result No wire problems. Wire problems are found. Action Action Go to test 7 Locate and repair or replace broken wire 1012 (Black/White) or adjacent wiring. Result 0Ω Action Go to test 3

Result Wire problems are found. Action Locate and repair or replace broken See the following for further testing wire 935/1087 or 935/1088 (Black) ENVIRONMENT CON- or adjacent wiring. • TROL Air-conditioning system - Problem solving HVAC (E.40.C) Result No wire problems. Action

84522361 15/06/2011

E.40.C / 26

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

Electronic A/C control - Testing HVAC Heat Components NOTE: Use schematics Wiring harness - Electrical schematic frame 17 (A.30.A) Test Point N° 1 Condition Disconnect connector X-252 from the TEMPCONTROL Z-017 potentiometer. With ignition on, Check for voltage from connector X-252 pin 3 and ground. 2 Condition Disconnect connector X-271 from the WATER VALVE Z-019. With ignition on, Check for voltage from connector X-271 pin A and ground. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-HVC1 pin 10 and connector X-271 pin A and between X-HVC1 pin 10 and connector X-252 pin 3.

Expected Result Result 12 V Action Go to test 2

Other Result (Possible Cause) Result 0V Action Go to test 3

Result 12 V Action Go to test 4

Result 0V Action Go to test 3

Result Wire problems are found. Action Locate and repair or replace broken See the following for further testing wire 823 (Pink) or 822/846/842 (OrENVIRONMENT CON- ange) or adjacent wiring. • TROL Air-conditioning system - Problem solving HVAC (E.40.C) Result No wire problems. Action

•

Electronic A/C control - Testing HVAC Box (E.40.C)

Result Result Varying resistance with potentiome- 0 Ω, or infinite resistance, or constant value ter movement. Action Action The TEMPCONTROL potentiometer Go to test 5 has failed. Replace the potentiometer. 5 Check Result Result 0 Ω, or greater than 1 K Ω for resistance between WATER 20 Ω Action Action VALVE Z-019 pins A and C. The WATER VALVE has failed. ReGo to test 6 place the valve. Result Result 6 Condition Wire problems are found. Use ELECTRICAL POWER SYS- No wire problems. Action TEM - Testing General Wire Test- Action Locate and repair or replace broken Go to test 7 ing (A.30.A) to wire 824 (Yellow). Check signal wire condition between X-252 pin 2 and connector X-271 pin D. 7 Condition Result Result Wire problems are found. Use ELECTRICAL POWER SYS- No wire problems. Action TEM - Testing General Wire Test- Action The WATER VALVE has failed. Re- Locate and repair or replace broken ing (A.30.A) to wire 912 (Black) or 1013 (Black). place the valve. Check ground wire condition between X-252 pin 1 and ground and between connector X-271 pin C and ground. 4 Check for resistance between TEMPCONTROL Z-017 potentiometer pins 2 and 3 while moving potentiometer.

84522361 15/06/2011

E.40.C / 27

FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system

Sensing system - Testing HVAC High Pressure Switch NOTE: Ensure the HVAC system has no mechanical problems before following this procedure. See ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC System (E.40.C) for more information on the HVAC System. NOTE: Use schematics Wiring harness - Electrical schematic frame 17 (A.30.A) Test Point N° 1 Condition Disconnect connector X-76 from the HVAC HIGH PRESSURE SWITCH. Connect a jumper between connector X-76 pins A and B. Check Use ENVIRONMENT CONTROL Air-conditioning system Overview HVAC System (E.40.C) to set up conditions for the A/C system to turn on. Check circuit operation. 2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-76 pin B and connector X-HVC1 pin 8. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-76 pin A and connector X-HVC1 pin 7.

Expected Result Result No circuit problems. Action The HVAC HIGH PRESSURE SWITCH has failed. Replace the switch.

Other Result (Possible Cause) Result No change in circuit response, remove jumper. Action Go to test 2

Result No wire problems. Action Go to test 3

Result Wire problems are found. Action Repair or replace broken wire 834 (White).

Result Wire problems are found. Action Repair or replace broken wire 833 See the following for further testing (White). Result No wire problems. Action

•

ENVIRONMENT CONTROL Air-conditioning system - Problem solving HVAC (E.40.C)

•

Electronic A/C control - Testing HVAC Box (E.40.C)

84522361 15/06/2011

E.40.C / 28

Index FRAME AND CAB - E ENVIRONMENT CONTROL Air-conditioning system - 40.C Compressor - Testing A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Condenser - Testing HVAC Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 ENVIRONMENT CONTROL Air-conditioning system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ENVIRONMENT CONTROL Air-conditioning system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . 4 ENVIRONMENT CONTROL Air-conditioning system - Overview HVAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENVIRONMENT CONTROL Air-conditioning system - Problem solving HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ENVIRONMENT CONTROL Air-conditioning system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Electronic A/C control - Overview HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electronic A/C control - Testing A/C Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Electronic A/C control - Testing Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Electronic A/C control - Testing HVAC Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Electronic A/C control - Testing HVAC Heat Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Sensing system - Testing HVAC High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

84522361 15/06/2011

E.40.C / 29

84522361 15/06/2011

E.40.C / 30

FRAME AND CAB - E SAFETY SECURITY ACCESSORIES Safety - 50.B

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

E.50.B / 1

Contents FRAME AND CAB - E SAFETY SECURITY ACCESSORIES Safety - 50.B

SERVICE Back up alarm Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DIAGNOSTIC Audible alert Testing Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84522361 15/06/2011

E.50.B / 2

FRAME AND CAB - SAFETY SECURITY ACCESSORIES Safety

Back up alarm - Remove 1.

2.

Locate and open engine hood (1) and rear service door (2).

93107449A1

1

931001672

2

931001673

3

Remove electrical leads (1) from the backup alarm H-002 (2).

3.

Remove hardware (1) retaining backup alarm H-002 (2).

4.

Remove backup alarm H-002 (2).

84522361 15/06/2011

E.50.B / 3

FRAME AND CAB - SAFETY SECURITY ACCESSORIES Safety

Back up alarm - Install 1.

2.

Insert retaining hardware and tighten bolts (1) securing the backup alarm H-002 (2).

931001673

1

931001672

2

Connect connectors X-BKUP-GND (1) and X-BKUP-PWR (2) to the backup alarm H-002 (3).

84522361 15/06/2011

E.50.B / 4

FRAME AND CAB - SAFETY SECURITY ACCESSORIES Safety

Audible alert - Testing Horn NOTE: Use schematics Wiring harness - Electrical schematic frame 04 (A.30.A) Wiring harness - Electrical schematic frame 07 (A.30.A) Test Point N° 1 Condition Remove IGNITION FUSE from the MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008. Check for continuity across IGNITION FUSE. 2 Condition With the fuse removed and ignition on, Check for voltage from MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C3 and ground. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-408 pin 4 (EH) X-405 pin A (Mech) and MAIN POWER DISTRIBUTION FUSE BLOCK 1 Z-2008 pin C4. 4 Check Using a multi-meter, check for resistance between HORN SWITCH S-023 X-408 pins 4 and 8 (EH) X-405 pins A and B (Mech) while cycling the switch.

Expected Result Result 0Ω Action Go to test 2

Other Result (Possible Cause) Result Fuse is blown. Action Replace the fuse with same type and amp rating.

Result 12 V Action Go to test 3

Result 0V Action There is a problem in the DC distribution system upstream of IGNITION FUSE.

Result No wire problems. Action Go to test 4

Result Wire problems are found. Action Locate and repair or replace broken wire 891/357/351 (Orange) or adjacent wiring.

Result For each resistance check, 0 Ω in one position, infinite resistance in the other. Action Go to test 5

5 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-408 pin 8 (EH) X-405 pin B (Mech) and connector X-HORN-PWR pin 1. 6 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-HORN-GND pin 1 and ground.

Result No wire problems. Action Go to test 6

Result 0 Ω in all positions or infinite resistance in all positions. Action The HORN SWITCH has failed. Replace the LEFT HAND CONTROL HANDLE. Result Wire problems are found. Action Locate and repair or replace broken wire 892 (White) or adjacent wiring.

Result Result Wire problems are found. No wire problems. Action Action The HORN has failed. Replace the Locate and repair or replace broken wire 955/968/983 (Black) or adjacent HORN. wiring.

84522361 15/06/2011

E.50.B / 5

Index FRAME AND CAB - E SAFETY SECURITY ACCESSORIES Safety - 50.B Audible alert - Testing Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Back up alarm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Back up alarm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

E.50.B / 6

84522361 15/06/2011

E.50.B / 7

New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

84522361 15/06/2011 EN

SERVICE MANUAL FRAME POSITIONING

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

F

Contents FRAME POSITIONING - F

STABILISING Ballasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F.20.B C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

F

FRAME POSITIONING - F STABILISING Ballasting - 20.B

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

F.20.B / 1

Contents FRAME POSITIONING - F STABILISING Ballasting - 20.B

SERVICE Rear ballasting Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L218, L220, L223, L225, L230, C227, C232, C238

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L213, L215

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L213, L215

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L218, L220, L223, L225, L230, C227, C232, C238

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 L218, L220, L223, L225, L230, C227, C232, C238

84522361 15/06/2011

F.20.B / 2

FRAME POSITIONING - STABILISING Ballasting

Rear ballasting - Remove L218, L220, L223, L225, L230, C227, C232, C238

Prior operation: Battery - Remove (A.30.A). 1.

2.

Remove left hand side corner mounting hardware (1).

931001655

1

931001658

2

93107449

3

Remove left hand side counterweight.

NOTE: Perform the same operation on the right hand side. 3.

Remove center bumper mounting hardware (1).

84522361 15/06/2011

F.20.B / 3

FRAME POSITIONING - STABILISING Ballasting

4.

Remove center bumper (3).

931001656

84522361 15/06/2011

F.20.B / 4

4

FRAME POSITIONING - STABILISING Ballasting

Rear ballasting - Remove L213, L215

1.

With proper support under the bumper weight remove mounting hardware (1).

2.

Remove center bumper .

931001656

84522361 15/06/2011

F.20.B / 5

1

FRAME POSITIONING - STABILISING Ballasting

Rear ballasting - Install L213, L215

1.

Place rear center bumper (1) in position.

931001656

2.

Install center bumper mounting hardware .

84522361 15/06/2011

F.20.B / 6

1

FRAME POSITIONING - STABILISING Ballasting

Rear ballasting - Remove L218, L220, L223, L225, L230, C227, C232, C238

Prior operation: Battery - Remove (A.30.A). 1.

2.

Remove left hand side corner mounting hardware (1).

931001655

1

931001658

2

931001656

3

Remove left hand side counterweight.

NOTE: Perform the same operation on the right hand side. 3.

Remove center bumper mounting hardware (1).

4.

Remove center bumper (2).

84522361 15/06/2011

F.20.B / 7

FRAME POSITIONING - STABILISING Ballasting

Rear ballasting - Install L218, L220, L223, L225, L230, C227, C232, C238

1.

Place rear center bumper (1) in position.

2.

Install center bumper mounting hardware (2).

3.

931001656

1

931001655

2

Install left hand side counterweight and secure in place with mounting hardware (3).

NOTE: Perform the came operation on right hand side. Next operation: Battery - Install (A.30.A).

84522361 15/06/2011

F.20.B / 8

Index FRAME POSITIONING - F STABILISING Ballasting - 20.B Rear ballasting - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L213, L215

Rear ballasting - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 L218, L220, L223, L225, L230, C227, C232, C238

Rear ballasting - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L218, L220, L223, L225, L230, C227, C232, C238

Rear ballasting - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L213, L215

Rear ballasting - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L218, L220, L223, L225, L230, C227, C232, C238

84522361 15/06/2011

F.20.B / 9

New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

84522361 15/06/2011 EN

SERVICE MANUAL TOOL POSITIONING

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

G

Contents TOOL POSITIONING - G

LIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.10.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

TILTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.20.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

LEVELLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.30.A C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

SECONDARY FUNCTIONS Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.90.C C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

G

TOOL POSITIONING - G LIFTING - 10.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

G.10.A / 1

Contents TOOL POSITIONING - G LIFTING - 10.A

TECHNICAL DATA Cylinder General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L218

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 L218

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L223, L225, L230, C232, C238

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L223, L225, L230, C232, C238

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L213, L215

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 C227

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 L220

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 L220

SERVICE Command Adjust for direct mechanical foot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 L213, L215, L218, L220, L223, L225, L230

Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C227, C232, C238

84522361 15/06/2011

G.10.A / 2

TOOL POSITIONING - LIFTING

Cylinder - General specification L218

Cylinder Collapsed length Extended length Stroke length Tube bore diameter Rod diameter Tube end diameter Rod end diameter End width Supply port size Return port size

Lift 983.0 mm (38.7 in) 1663.7 mm (65.5 in) 680.7 mm (26.8 in) 57.2 mm (2.3 in) 34.9 mm (1.4 in) 38.2 mm (1.5 in) 38.2 mm (1.5 in) 40.6 mm (1.6 in) 3/4-16 SAE O-ring boss 3/4-16 SAE O-ring boss

84522361 15/06/2011

G.10.A / 3

TOOL POSITIONING - LIFTING

Cylinder - General specification L218

Cylinder Collapsed length Extended length Stroke length Tube bore diameter Rod diameter Tube end diameter Rod end diameter End width Supply port size Return port size

Lift 983.0 mm (38.7 in) 1663.7 mm (65.5 in) 680.7 mm (26.8 in) 57.2 mm (2.3 in) 34.9 mm (1.4 in) 38.2 mm (1.5 in) 38.2 mm (1.5 in) 40.6 mm (1.6 in) 3/4-16 SAE O-ring boss 3/4-16 SAE O-ring boss

84522361 15/06/2011

G.10.A / 4

TOOL POSITIONING - LIFTING

Cylinder - General specification L223, L225, L230, C232, C238

Cylinder Collapsed length Extended length Stroke length Tube bore diameter Rod diameter Tube end diameter Rod end diameter Tube end width Rod end width Supply port size Return port size

Lift 1191.3 mm (46.9 in) 2044.7 mm (80.5 in) 850.9 mm (33.5 in) 63.5 mm (2.5 in) 44.4 mm (1.7 in) 38.2 mm (1.5 in) 38.2 mm (1.5 in) 40.6 mm (1.6 in) 50.8 mm (2 in) 3/4-16 SAE O-ring boss 3/4-16 SAE O-ring boss

84522361 15/06/2011

G.10.A / 5

TOOL POSITIONING - LIFTING

Cylinder - General specification L223, L225, L230, C232, C238

Cylinder Collapsed length Extended length Stroke length Tube bore diameter Rod diameter Tube end diameter Rod end diameter Tube end width Rod end width Supply port size Return port size

Lift 1191.3 mm (46.9 in) 2044.7 mm (80.5 in) 850.9 mm (33.5 in) 63.5 mm (2.5 in) 44.4 mm (1.7 in) 38.2 mm (1.5 in) 38.2 mm (1.5 in) 40.6 mm (1.6 in) 50.8 mm (2 in) 3/4-16 SAE O-ring boss 3/4-16 SAE O-ring boss

84522361 15/06/2011

G.10.A / 6

TOOL POSITIONING - LIFTING

Cylinder - General specification L213, L215

Cylinder Collapsed length Stroke length Tube bore diameter Rod diameter Tube end pin diameter Rod end pin diameter Rod end width Tube end width Tube port size Rod port size

Lift 989 mm (38.9 in) 645 mm (25.4 in) 57.2 mm (2.3 in) 34.9 mm (1.4 in) 38.3 mm (1.5 in) 38.3 mm (1.5 in) 40 mm (1.6 in) 40 mm (1.6 in) 3/4-16 SAE O-ring boss 3/4-16 SAE O-ring boss

84522361 15/06/2011

G.10.A / 7

TOOL POSITIONING - LIFTING

Cylinder - General specification C227

Cylinder Collapsed length Extended length Stroke length Tube bore diameter Rod diameter Tube end diameter Rod end diameter Tube end width Rod end width Supply port size Return port size

Lift 1158.2 mm (45.6 in) 1963.4 mm (77.3 in) 805.2 mm (31.7 in) 63.5 mm (2.5 in) 44.4 mm (1.7 in) 38.3 mm (1.5 in) 38.3 mm (1.5 in) 40.6 mm (1.6 in) 50.8 mm (2 in) 3/4-16 SAE O-ring boss 3/4-16 SAE O-ring boss

84522361 15/06/2011

G.10.A / 8

TOOL POSITIONING - LIFTING

Cylinder - General specification L220

Cylinder Collapsed length Extended length Stroke length Tube bore diameter Rod diameter Tube end diameter Rod end diameter End width Supply port size Return port size

Lift 983.0 mm (38.7 in) 1663.7 mm (65.5 in) 680.7 mm (26.8 in) 57.2 mm (2.3 in) 34.9 mm (1.4 in) 38.2 mm (1.5 in) 38.2 mm (1.5 in) 40.6 mm (1.6 in) 3/4-16 SAE O-ring boss 3/4-16 SAE O-ring boss

84522361 15/06/2011

G.10.A / 9

TOOL POSITIONING - LIFTING

Cylinder - General specification L220

Cylinder Collapsed length Extended length Stroke length Tube bore diameter Rod diameter Tube end diameter Rod end diameter End width Supply port size Return port size

Lift 983.0 mm (38.7 in) 1663.7 mm (65.5 in) 680.7 mm (26.8 in) 57.2 mm (2.3 in) 34.9 mm (1.4 in) 38.2 mm (1.5 in) 38.2 mm (1.5 in) 40.6 mm (1.6 in) 3/4-16 SAE O-ring boss 3/4-16 SAE O-ring boss

84522361 15/06/2011

G.10.A / 10

TOOL POSITIONING - LIFTING

Command - Adjust for direct mechanical foot controls L213, L215, L218, L220, L223, L225, L230

Adjustment for direct mechanical foot controls 1.

Raise machine off ground and place securely on jack stands.

2.

Loosen Clamp Bolts (1), but leave snug.

3.

Take engine to high idle.

4.

Move wear plate until pump is centered.

5.

Tighten clamp bolts and move handle in both directions to confirm neutral is set. Adjust again if needed.

6.

Repeat for other pump.

7.

Set handle position by loosing the left hand thread jam nut (2) and right hand thread jam nut (3) and rotating the control rod (4) until handle is in the correct position of 75 °. Then tighten both jam nuts.

8.

Set travel stops. Refer to Direct Hand Control instructions for details. STEERING Mechanical - Adjust for hand controls with direct mechanical hydrostatic pump (D.20.B)

84522361 15/06/2011

G.10.A / 11

23112917

1

23112918

2

23112922

3

TOOL POSITIONING - LIFTING

Command - Adjust C227, C232, C238

1.

2.

Remove Tag along springs (1) (both sides).

23112920

1

23112922

2

23112919A

3

Set handle position by loosening left hand jam nut (2) and right hand jam nut (3) and rotating control rod (6) until handle is in the correct position, of 75 ° then tighten the jam nuts.

3.

Loosen roller (4) and position in center of cam (5). Then tighten the roller.

4.

Reinstall the Tag along springs that was removed in the 1st step.

5.

Repeat steps 2 and 3 for other pump.

6.

Set stop bolts and drift – Same as Direct Mechanical. STEERING Mechanical - Adjust for hand controls with direct mechanical hydrostatic pump (D.20.B)

7.

See Servo Hand Controls for instructions to align Handles after setting drift. STEERING Mechanical Adjust hand controls with servo operated pump (D.20.B)

84522361 15/06/2011

G.10.A / 12

Index TOOL POSITIONING - G LIFTING - 10.A Command - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C227, C232, C238

Command - Adjust for direct mechanical foot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 L213, L215, L218, L220, L223, L225, L230

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L218

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 L218

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L223, L225, L230, C232, C238

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L223, L225, L230, C232, C238

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L213, L215

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 C227

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 L220

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 L220

84522361 15/06/2011

G.10.A / 13

84522361 15/06/2011

G.10.A / 14

TOOL POSITIONING - G TILTING - 20.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

G.20.A / 1

Contents TOOL POSITIONING - G TILTING - 20.A

TECHNICAL DATA Cylinder General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L213, L215

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 C227

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L218

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L220

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L223, L225, L230, C232, C238

84522361 15/06/2011

G.20.A / 2

TOOL POSITIONING - TILTING

Cylinder - General specification L213, L215

Cylinder Collapsed length Stroke length Tube bore diameter Rod diameter Tube end pin diameter Rod end pin diameter Tube end width Rod end width Tube end port size Rod end port size

Bucket 594 mm (23.4 in) 370 mm (14.6 in) 57.2 mm (2.3 in) 31.7 mm (1.2 in) 38.1 mm (1.5 in) 38.3 mm (1.5 in) 76 mm (3 in) 46 mm (1.8 in) 9/16-18 UNF-2B SAE O-ring boss 9/16-18 UNF-2B SAE O-ring boss

84522361 15/06/2011

G.20.A / 3

TOOL POSITIONING - TILTING

Cylinder - General specification C227

Cylinder Collapsed length Extended length Stroke length Tube bore diameter Rod diameter Tube end diameter Rod end diameter Tube end width Supply port size Return port size

Tilt 609.6 mm (24 in) 1021.1 mm (40.2 in) 408.9 mm (16.1 in) 69.9 mm (2.8 in) 34.9 mm (1.4 in) 44.5 mm (1.8 in) 38.3 mm (1.5 in) 76.2 mm (3 in) 9/16-18 UNF-2B SAE O-ring boss 9/16-18 UNF-2B SAE O-ring boss

84522361 15/06/2011

G.20.A / 4

TOOL POSITIONING - TILTING

Cylinder - General specification L218

Cylinder Collapsed length Stroke length Tube bore diameter Rod diameter Tube end pin diameter Tube end width Rod end pin diameter Rod end width Supply port size Return port size

Bucket 610 mm (24 in) 410 mm (16.1 in) 63.5 mm (2.5 in) 34.9 mm (1.4 in) 44.5 mm (1.8 in) 76 mm (3 in) 38.3 mm (1.5 in) 45.7 mm (1.8 in) 9/16-18 UNF-2B SAE O-ring boss 9/16-18 UNF-2B SAE O-ring boss

84522361 15/06/2011

G.20.A / 5

TOOL POSITIONING - TILTING

Cylinder - General specification L220

Cylinder Collapsed length Collapsed length Stroke length Tube bore diameter Rod diameter Tube end diameter Rod end diameter Tube end width Supply port size Return port size

Tilt 609.6 mm (24 in) 1021.1 mm (40.2 in) 408.9 mm (16.1 in) 69.9 mm (2.8 in) 34.9 mm (1.4 in) 44.5 mm (1.8 in) 38.3 mm (1.5 in) 76.2 mm (3 in) 9/16-18 UNF-2B SAE O-ring boss 9/16-18 UNF-2B SAE O-ring boss

84522361 15/06/2011

G.20.A / 6

TOOL POSITIONING - TILTING

Cylinder - General specification L223, L225, L230, C232, C238

Cylinder Collapsed length Extended length Stroke length Tube bore diameter Rod diameter Tube end diameter Rod end diameter Tube end width Supply port size Return port size

Tilt 609.6 mm (24 in) 1021.1 mm (40.2 in) 408.9 mm (16.1 in) 76.1 mm (3.0 in) 38.1 mm (1.5 in) 44.5 mm (1.8 in) 38.3 mm (1.5 in) 76.2 mm (3 in) 9/16-18 UNF-2B SAE O-ring boss 9/16-18 UNF-2B SAE O-ring boss

84522361 15/06/2011

G.20.A / 7

Index TOOL POSITIONING - G TILTING - 20.A Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L213, L215

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 C227

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L218

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 L220

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L223, L225, L230, C232, C238

84522361 15/06/2011

G.20.A / 8

TOOL POSITIONING - G LEVELLING - 30.A

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

G.30.A / 1

Contents TOOL POSITIONING - G LEVELLING - 30.A

TECHNICAL DATA Control valve General specification of the 60% self level valve on medium and large frame . . . . . . . . . . . . . . . . . . . . . . . 3 L220, L225, L230, C232, C238

General specification of the 48% self level valve on small frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L213, L215

General specification of the 50% self level valve on medium frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 C227

General specification of the 40% self level valve on medium frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L218

SERVICE Command Remove Self Level Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install Self Level Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Command valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Control valve Remove Self level valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install Self level valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

84522361 15/06/2011

G.30.A / 2

TOOL POSITIONING - LEVELLING

Control valve - General specification of the 60% self level valve on medium and large frame L220, L225, L230, C232, C238

Manufacturer

Eaton - Part Number 39055-EEG

Proportional Flow Divider Settings:

Port D = 60 % Port B = 40 %

Hydraulic Requirements:

Flow = 57 l/min (15 US gpm) System Pressure = 210 bar (3050 psi)

Electrical Requirements:

Operating Voltage = 14 V Maximum Power = 22 W Self Level Override Solenoid Connection Type: Deutsch DT series.

Proportional Flow Divider Adjustment: Remove plastic cap. Turn counter clockwise to increase flow to the tilt cylinders. Turn clockwise to decrease flow to the tilt cylinders. Operating Temperature Range:

-30 - 107 °C (-22 - 225 °F)

Port Identification Chart:

(A) (B) (C) (D)

Lift Cylinder Rod End CV Work Port B1 Tilt Cylinder Rod End Tilt Cylinder Base End

Control valve - General specification of the 48% self level valve on small frame L213, L215

Manufacturer

Eaton - Part Number 39055-EEJ

Proportional Flow Divider Settings:

Port D = 48 % Port B = 52 %

Hydraulic Requirements:

Flow = 57 l/min (15 US gpm) System Pressure = 210 bar (3050 psi) Operating Voltage = 14 V Maximum Power = 22 W Self Level Override Solenoid Connection Type: Deutsch DT series.

Electrical Requirements:

Proportional Flow Divider Adjustment: Remove plastic cap. Turn counter clockwise to increase flow to the tilt cylinders. Turn clockwise to decrease flow to the tilt cylinders. Operating Temperature Range:

-30 - 107 °C (-22 - 225 °F)

Port Identification Chart:

(A) (B) (C) (D)

Lift Cylinder Rod End CV Work Port B1 Tilt Cylinder Rod End Tilt Cylinder Base End

84522361 15/06/2011

G.30.A / 3

TOOL POSITIONING - LEVELLING

Control valve - General specification of the 50% self level valve on medium frame C227

Manufacturer

Eaton - Part Number 39055-EEH

Proportional Flow Divider Settings:

Port D = 50 % Port B = 50 %

Hydraulic Requirements:

Flow = 57 l/min (15 US gpm) System Pressure = 210 bar (3050 psi) Intermittent Pressure Spikes = 276 bar (4000 psi) Maximum Pressure Drop Across Valve = 10 bar (150 psi) @ 57 l/min (15 US gpm)

Electrical Requirements:

Operating Voltage = 14 V Maximum Power = 22 W Self Level Override Solenoid Connection Type: Deutsch DT series.

Proportional Flow Divider Adjustment: Remove plastic cap. Turn counter clockwise to increase flow to the tilt cylinders. Turn clockwise to decrease flow to the tilt cylinders. Operating Temperature Range:

-30 - 107 °C (-22 - 225 °F)

Port Identification Chart:

(A) (B) (C) (D)

Lift Cylinder Rod End CV Work Port B1 Tilt Cylinder Rod End Tilt Cylinder Base End

84522361 15/06/2011

G.30.A / 4

TOOL POSITIONING - LEVELLING

Control valve - General specification of the 40% self level valve on medium frame L218

Manufacturer

Eaton - Part Number 39055-EEK

Proportional Flow Divider Settings:

Port D = 40 % Port B = 60 %

Hydraulic Requirements:

Flow = 57 l/min (15 US gpm) System Pressure = 210 bar (3050 psi) Operating Voltage = 14 V Maximum Power = 22 W Self Level Override Solenoid Connection Type: Deutsch DT series.

Electrical Requirements:

Proportional Flow Divider Adjustment: Remove plastic cap. Turn counter clockwise to increase flow to the tilt cylinders. Turn clockwise to decrease flow to the tilt cylinders. Operating Temperature Range:

-30 - 107 °C (-22 - 225 °F)

Port Identification Chart:

(A) (B) (C) (D)

Lift Cylinder Rod End CV Work Port B1 Tilt Cylinder Rod End Tilt Cylinder Base End

84522361 15/06/2011

G.30.A / 5

TOOL POSITIONING - LEVELLING

Command - Remove Self Level Valve Solenoid Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

Locate self level valve solenoid Y-318 on the right side, middle of the machine.

931001804

1

931001701

2

931001702

3

Disconnect connector X-318 from the self level valve solenoid Y-318.

Loosen and remove nut (1). Remove the self level valve solenoid Y-318.

Next operation: Command - Install Self Level Valve Solenoid (G.30.A)

84522361 15/06/2011

G.30.A / 6

TOOL POSITIONING - LEVELLING

Command - Install Self Level Valve Solenoid Prior operation: Command - Remove Self Level Valve Solenoid (G.30.A) 1.

2.

3.

Insert the self level valve solenoid Y-318 (1) into the valve block (2).

931001702

1

931001701

2

931001701

3

Thread nut on stud and tighten to standard torque.

Reconnect connector X-318 (1) to the self level valve solenoid Y-318 (2).

84522361 15/06/2011

G.30.A / 7

TOOL POSITIONING - LEVELLING

Command valve - Remove 1.

2.

3.

4.

Label and disconnect electrical connection.

931001722

1

931001720

2

931001720

3

931001720

4

Label and disconnect bucket hydraulic tubes (1) and cap open ports.

Label and disconnect supply tube and cap open ports.

label and disconnect drain hose.

84522361 15/06/2011

G.30.A / 8

TOOL POSITIONING - LEVELLING

5.

6.

Remove mounting hardware (2).

931001720

5

931001721

6

Remove command valve.

84522361 15/06/2011

G.30.A / 9

TOOL POSITIONING - LEVELLING

Command valve - Install 1.

2.

3.

4.

locate where the command valve is positioned on the body.

931001720

1

931001720

2

931001720

3

931001720

4

Install mounting hardware (1).

Connect valve drain hose.

Connect valve supply tube.

84522361 15/06/2011

G.30.A / 10

TOOL POSITIONING - LEVELLING

5.

6.

Connect bucket hydraulic tubes (2).

931001720

5

931001722

6

Connect electrical connection.

84522361 15/06/2011

G.30.A / 11

TOOL POSITIONING - LEVELLING

Control valve - Remove Self level valve Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

4.

Locate control valve.

931001804

1

931001701

2

931001702

3

931001981

4

Disconnect electrical connection

Disconnect hydraulic tube and cap open ports.

Disconnect lower tubes (1) and cap ports.

84522361 15/06/2011

G.30.A / 12

TOOL POSITIONING - LEVELLING

5.

6.

7.

Disconnect front tube (1) and cap port.

931001981

5

931001981

6

931001707

7

Remove mounting hardware (1).

Remove control valve.

84522361 15/06/2011

G.30.A / 13

TOOL POSITIONING - LEVELLING

Control valve - Install Self level valve 1.

2.

3.

4.

Install control valve (1) onto body in correct location.

931001804

1

931001981

2

931001981

3

931001981

4

Install mounting hardware (1).

Connect front tube (1).

Connect lower tubes (1).

84522361 15/06/2011

G.30.A / 14

TOOL POSITIONING - LEVELLING

5.

6.

Connect hydraulic tube (1).

931001702

5

931001701

6

Connect electrical connection (1).

Next operation: Tilt system - Lower (E.34.A)

84522361 15/06/2011

G.30.A / 15

Index TOOL POSITIONING - G LEVELLING - 30.A Command - Install Self Level Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Command - Remove Self Level Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Command valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Command valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Control valve - General specification of the 40% self level valve on medium frame . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L218

Control valve - General specification of the 48% self level valve on small frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L213, L215

Control valve - General specification of the 50% self level valve on medium frame . . . . . . . . . . . . . . . . . . . . . . . . . . 4 C227

Control valve - General specification of the 60% self level valve on medium and large frame . . . . . . . . . . . . . . . . . 3 L220, L225, L230, C232, C238

Control valve - Install Self level valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Control valve - Remove Self level valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

84522361 15/06/2011

G.30.A / 16

TOOL POSITIONING - G SECONDARY FUNCTIONS Hydraulic - 90.C

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

G.90.C / 1

Contents TOOL POSITIONING - G SECONDARY FUNCTIONS Hydraulic - 90.C

FUNCTIONAL DATA Control valve Overview High Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview Auxiliary Override Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DIAGNOSTIC Control valve Testing 2nd Aux Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Testing 2nd Aux Retract Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Testing 2nd Aux Hyd Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Testing High Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84522361 15/06/2011

G.90.C / 2

TOOL POSITIONING - SECONDARY FUNCTIONS Hydraulic

Control valve - Overview High Flow The Operator can command additional flow to the auxiliary circuit by engaging Auxiliary High flow Function. This will provide increase flow and pressure to the auxiliary circuit. Of up to 128 l/min (35 US gpm) and up to 215 bar (3050 psi). High Flow feature is engaged by pressing the On/Off switch mounted on left hand A post. The switch selects Standard or Enhance High Flow and is illuminated when High Flow or Enhanced High Flow is on. Allows the operator to enable/ disable the function depending on the attachment requirements. The attachment flow is controlled with the switch in the Left Hand Control Handle. The External Auxiliary Control can be controlled ONLY if ALL of the following conditions are met 1.

Operator is seated properly

2.

Operator Restraint engaged

3.

The ignition is in the ON position

4.

Hydraulic Enable switch is activated

The Operator can command additional pressure to the auxiliary circuit by engaging the Enhanced Auxiliary High flow function. This will provide increase pressure to the auxiliary circuit. Flow is 128 l/min (35 US gpm) and pressure up to 275 bar (4000 psi). The loader control valve standard auxiliary circuit is unaffected when High Flow is disabled. When Standard or Enhanced High Flow is enabled the loader control valve standard auxiliary circuit is limited to 2nd Aux circuit flow of 30.3 l/min (8 US gpm). The 275 bar (4000 psi) High Flow setting can only be used with approved attachments and is controlled by a circuit interlock installed at the multifunction plug with the attachment. High Flow feature is engaged by pressing the On/Off switch mounted on left hand A post. Allows the operator to enable/disable the function depending on the attachment requirements. The Enhanced High Flow Auxiliary Control can be controlled only if all of the following conditions are met 1.

Operator is seated properly

2.

Operator Restraint engaged

3.

The ignition is in the ON position

4.

Engine is running

5.

Hydraulic Enable switch is activated

6.

Multifunction high pressure interlock plug connected ("HP" mode only)

84522361 15/06/2011

G.90.C / 3

TOOL POSITIONING - SECONDARY FUNCTIONS Hydraulic

Control valve - Overview Auxiliary Override Control The machine can be used to operate auxiliary attachments which require the operator to exit the cab. The operator can engage the auxiliary hydraulics such that they will remain on full flow so that the attachment will be provide hydraulic lines for P and T. The attachment will most likely contain its own control valve. Operator must press the Auxiliary Hydraulic Interlock Override switch on the instrument cluster. This will override the seat switch and restraint bar. A lamp will flash indicating that the override is activated and the operator must leave the seat within 30 seconds otherwise the feature will deactivate. When the button is pressed (press and release within 10 sec) the following conditions will be set 1.

Park brake engaged

2.

Loader arm and bucket disabled

3.

Engage port locks

4.

Loader Pilot interlock unlocked

The operator can put the thumbwheel into the forward detented position, before or after Aux Override is pressed. Any reverse flow command will be ignored. If the operator does not leave the seat within 30 seconds, the SSL will go into hydraulics disable state and the operator must re-enabled hydraulics to regain control of the machine. When the operator re-enters the SSL AND the seat switch THEN lap bar are down, the machine will enter hydraulics disable state. Otherwise Aux override will remain active. He will have to meet the Hydraulics Enable Function Enable Conditions to re-enable hydraulics. At any time the Aux override or the hydraulics enable button can be pressed to deactivate the feature. Auxiliary Override is functional with the standard flow and high flow. Not allowed with enhanced high flow option. The Auxiliary Override Feature can be activated only if all of the following conditions are met 1.

Operator is seated properly

2.

Operator Restraint is engaged

3.

The ignition is in the ON position

4.

Hydraulic Enable switch is activated

Valve Logic Port Lock Park Brake Ground Drive Interlock Loader Interlock

Enabled Locked Activated Locked Unlocked

Disabled not controlled not controlled not controlled not controlled

84522361 15/06/2011

G.90.C / 4

TOOL POSITIONING - SECONDARY FUNCTIONS Hydraulic

Control valve - Testing 2nd Aux Extend Solenoid NOTE: Use schematics Wiring harness - Electrical schematic frame 07 (A.30.A) Wiring harness - Electrical schematic frame 15 (A.30.A) Test Point N° 1 Condition Disconnect connector X-AUX_EXT from the 2ND AUX EXTEND SOLENOID Check for resistance between 2ND AUX EXTEND SOLENOID pins 1 and 2 (EH) pins A and B (Mech). 2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-AUX_EXT pin 2 (EH) pin B (Mech) and ground. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-AUX_EXT pin 1 (EH) pin A (Mech) and connector X-408 (EH) X-407 (Mech) pin 2.

Expected Result Result Normal resistance. Action Go to test 2

Other Result (Possible Cause) Result 0 Ω, or greater than 1 K Ω Action The 2ND AUX EXTEND SOLENOID has failed. Replace the solenoid.

Result No wire problems. Action Go to test 3

Result Wire problems are found. Action Repair or replace broken wire 958/ 1008/1014 (Black).

Result Wire problems are found. Action Repair or replace broken wire See the following for further testing 554 (White) (EH) 554/454 (White) Control valve - Testing (Mech). • 2nd Aux Hyd Switch (G.90.C) Result No wire problems. Action

•

Control valve - Testing High Flow Switch (G.90.C)

•

Electrical control - Testing Hydraulic Coupler Switch and Solenoid (J.80.C)

•

OPTION RELAY in ELECTRICAL POWER SYSTEM - Component identification Relay Index (A.30.A)

84522361 15/06/2011

G.90.C / 5

TOOL POSITIONING - SECONDARY FUNCTIONS Hydraulic

Control valve - Testing 2nd Aux Retract Solenoid NOTE: Use schematics Wiring harness - Electrical schematic frame 07 (A.30.A) Wiring harness - Electrical schematic frame 15 (A.30.A) Test Point N° 1 Condition Disconnect connector X-AUX_RET from the 2ND AUX RETRACT SOLENOID Check for resistance between 2ND AUX RETRACT SOLENOID pins 1 and 2 (EH) pins A and B (Mech). 2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-AUX_RET pin 2 (EH) pin B (Mech) and ground. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-AUX_RET pin 1 (EH) pin A (Mech) and connector X-408 (EH) X-407 (Mech) pin 3.

Expected Result Result Normal resistance. Action Go to test 2

Other Result (Possible Cause) Result 0 Ω, or greater than 1 K Ω Action The 2ND AUX RETRACT SOLENOID has failed. Replace the solenoid.

Result No wire problems. Action Go to test 3

Result Wire problems are found. Action Repair or replace broken wire 959/ 1008/1014 (Black).

Result Wire problems are found. Action Repair or replace broken wire 552 See the following for further testing (White). Result No wire problems. Action

•

Control valve - Testing 2nd Aux Hyd Switch (G.90.C)

•

Control valve - Testing High Flow Switch (G.90.C)

•

Electrical control - Testing Hydraulic Coupler Switch and Solenoid (J.80.C)

•

OPTION RELAY in ELECTRICAL POWER SYSTEM - Component identification Relay Index (A.30.A)

84522361 15/06/2011

G.90.C / 6

TOOL POSITIONING - SECONDARY FUNCTIONS Hydraulic

Control valve - Testing 2nd Aux Hyd Switch NOTE: Use schematics Wiring harness - Electrical schematic frame 05 (A.30.A) Wiring harness - Electrical schematic frame 07 (A.30.A) Test Point N° 1 Condition Remove HIGH FLOW / COUPLER FUSE from the ACCESSORY POWER DISTRIBUTION. Check for continuity across HIGH FLOW / COUPLER FUSE. 2 Condition With the fuse removed and ignition on, Check for voltage from ACCESSORY POWER DISTRIBUTION pin E11 and ground. 3 Condition Disconnect connector X-408 (EH) X-407 (Mech). Check Using a multi-meter, check for resistance between LEFT HAND CONTROL HANDLE pins 1 and 2 pins 1 and 3 while cycling the 2ND AUX HYD SWITCH S-033. 4 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between ACCESSORY POWER DISTRIBUTION pin E12 and connector X-408 pin 1.

Expected Result Result 0Ω Action Go to test 2

Other Result (Possible Cause) Result Fuse is blown. Action Replace the fuse with same type and amp rating.

Result 0V Action There is a problem in the DC distribution system upstream of HIGH FLOW / COUPLER FUSE. Result Result For each resistance check, 0 Ω in 0 Ω in multiple positions or infinite one position, infinite resistance in all resistance in all positions. Action others. The 2ND AUX HYD SWITCH has failed. Action Replace the LEFT HAND CONTROL Go to test 4 HANDLE.

Result 12 V Action Go to test 3

Result Wire problems are found. Action Locate and repair or replace broken See the following for further testing wire 558/744 (Orange) or adjacent Control valve - Testing wiring. • 2nd Aux Extend Solenoid (G.90.C) Result No wire problems. Action

•

Control valve - Testing High Flow Switch (G.90.C)

•

Electrical control - Testing Hydraulic Coupler Switch and Solenoid (J.80.C)

84522361 15/06/2011

G.90.C / 7

TOOL POSITIONING - SECONDARY FUNCTIONS Hydraulic

Control valve - Testing High Flow Switch NOTE: Use schematics Wiring harness - Electrical schematic frame 05 (A.30.A) Wiring harness - Electrical schematic frame 06 (A.30.A) Test Point N° 1 Condition Remove HIGH FLOW / COUPLER FUSE from the ACCESSORY POWER DISTRIBUTION. Check for continuity across HIGH FLOW / COUPLER FUSE. 2 Condition With the fuse removed and ignition on, Check for voltage from ACCESSORY POWER DISTRIBUTION pin E11 and ground. 3 Condition Disconnect connector X-303 from the HIGH FLOW SWITCH. Reconnect all other connectors. Connect a jumper between connector X-303 pins B and C. Check Check circuit operation. 4 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between ACCESSORY POWER DISTRIBUTION pin E12 and connector X-303 pin B.

Expected Result Result 0Ω Action Go to test 2

Other Result (Possible Cause) Result Fuse is blown. Action Replace the fuse with same type and amp rating.

Result 0V Action There is a problem in the DC distribution system upstream of HIGH FLOW / COUPLER FUSE. Result Result No change in circuit response, reNo circuit problems. move jumper. Action The HIGH FLOW SWITCH has failed. Action Go to test 4 Replace the switch.

Result 12 V Action Go to test 3

Result Wire problems are found. Action Locate and repair or replace broken See the following for further testing wire 753/744 (Orange) or adjacent Control valve - Testing wiring. • 2nd Aux Hyd Switch (G.90.C) Result No wire problems. Action

•

Hydraulic line - Testing Std High Flow Solenoid (H.20.B)

84522361 15/06/2011

G.90.C / 8

Index TOOL POSITIONING - G SECONDARY FUNCTIONS Hydraulic - 90.C Control valve - Overview Auxiliary Override Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Control valve - Overview High Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Control valve - Testing 2nd Aux Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Control valve - Testing 2nd Aux Hyd Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Control valve - Testing 2nd Aux Retract Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Control valve - Testing High Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84522361 15/06/2011

G.90.C / 9

New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

84522361 15/06/2011 EN

SERVICE MANUAL HITCH AND WORKING TOOL

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

H

Contents HITCH AND WORKING TOOL - H

BOOM Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.20.B C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

ARM TOOL ATTACHMENT Tilt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.30.C C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

SINGLE ARM Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.40.B C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

SINGLE ARM TOOL ATTACHMENT Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.50.C C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

H

HITCH AND WORKING TOOL - H BOOM Lift - 20.B

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

H.20.B / 1

Contents HITCH AND WORKING TOOL - H BOOM Lift - 20.B

DIAGNOSTIC Control valve Testing Loader Lockout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Hydraulic line Testing Std High Flow Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84522361 15/06/2011

H.20.B / 2

HITCH AND WORKING TOOL - BOOM Lift

Control valve - Testing Loader Lockout Switch L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

NOTE: Wiring Wiring Wiring

Use schematics harness - Electrical schematic frame 03 (A.30.A) harness - Electrical schematic frame 06 (A.30.A) harness - Electrical schematic frame 26 (A.30.A)

Test Point N° 1 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-306 pin B and connector X-C23 pin 23. 2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-306 pin A and connector X-CN3B pin 26. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-306 pin C and connector X-CN2B pin 22. 4 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-306 pin E and ground. 5 Condition Use Data bus - General specification Instrument Cluster pin information (A.50.A) to check Instrument Cluster pin 23.

Expected Result Result No wire problems Action Go to test 2

Other Result (Possible Cause) Action If wire problems are found, repair or replace broken wire 301 (Orange) / 305 (Yellow) / 311 (Orange).

Result No wire problems Action Go to test 3

Action If wire problems are found, repair or replace broken wire 312 (Yellow).

Result No wire problems Action Go to test 4

Action If wire problems are found, repair or replace broken wire 398 (Yellow).

Result No wire problems Action Go to test 5

Action If wire problems are found, repair or replace broken wire 924/ 941/942/1090 (Black).

Action Result If resistance problems are found, No resistance problems replace the Instrument Cluster. Action The Loader Lockout Switch S-005 has failed. Replace the Loader Lockout Switch S-005.

84522361 15/06/2011

H.20.B / 3

HITCH AND WORKING TOOL - BOOM Lift

Hydraulic line - Testing Std High Flow Solenoid NOTE: Use schematics Wiring harness - Electrical schematic frame 06 (A.30.A) Wiring harness - Electrical schematic frame 25 (A.30.A) (EH) Wiring harness - Electrical schematic frame 02 (A.30.A) (Mech) Test Point N° 1 Condition Disconnect connector X-HFLO from the HIGH FLOW SOLENOID Check for resistance between HIGH FLOW SOLENOID pins 1 and 2. 2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between connector X-HFLO pin 1 and ground. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to Check wire condition between X-HFLO pin 2 and connector X-303 pin C.

Expected Result Result Normal resistance. Action Go to test 2

Other Result (Possible Cause) Result 0 Ω, or greater than 1 K Ω Action The HIGH FLOW SOLENOID has failed. Replace the solenoid.

Result No wire problems. Action Go to test 3

Result Wire problems are found. Action Repair or replace broken wire 976/ 984 (Black).

Result No wire problems. Action See Control valve - Testing High Flow Switch (G.90.C) for further testing.

Result Wire problems are found. Action Repair or replace broken wire 750 (White).

84522361 15/06/2011

H.20.B / 4

Index HITCH AND WORKING TOOL - H BOOM Lift - 20.B Control valve - Testing Loader Lockout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L213 Electro hydraulic controls, L215 Electro hydraulic controls, L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Hydraulic line - Testing Std High Flow Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84522361 15/06/2011

H.20.B / 5

84522361 15/06/2011

H.20.B / 6

HITCH AND WORKING TOOL - H ARM TOOL ATTACHMENT Tilt - 30.C

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

H.30.C / 1

Contents HITCH AND WORKING TOOL - H ARM TOOL ATTACHMENT Tilt - 30.C

SERVICE Relief valve Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84522361 15/06/2011

H.30.C / 2

HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt

Relief valve - Pressure test PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A) 1.

Park the machine on a level surface.

2.

Lower all attachments to the floor.

3.

Stop the engine.

4.

Move the control levers in all directions to release any circuit pressure.

5.

The best way to connect the hand pump is directly to the control valve. Disconnect the tube from the port of the control valve and connect the hand pump to the port. By connecting directly to the control valve, you avoid the possibility of a bad reading because of cylinder movement.

6.

Remove all dirt and grease from the connecting point.

7.

Connect the hose of the hand pump to the connecting point, but do not tighten the connection.

8.

Make sure that the hand pump is filled with oil. The temperature of the oil must be at least 21°C (70°F).

9.

Operate the hand pump to fill the hose of the hand pump with oil. Then tighten the connections.

10.

Operate the hand pump and read the pressure gauge. Record the highest indication. Check the pressure several times to make sure that the indications are correct.

11.

Compare the indication with the specification Pump - General specification (C.20.F). If the indication is not correct, replace the circuit relief valve.

NOTE: The circuit relief valves for the loader circuit are not adjustable and must be replaced if they do not meet the specification. 12.

Repeat this test after installing a new circuit relief valve.

84522361 15/06/2011

H.30.C / 3

HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt

Relief valve - Flow test Prior operation: Relief valve - Flow test (A.10.A) Relief valve - Flow test (A.10.A) . 1.

Start the engine and run the engine at 2300 r/min (rpm).

2.

Hold the bucket control lever in the ROLLBACK position and close the pressure valve on the flowmeter until the pressure gauge indicates 124 bar (1800 psi). Adjust the engine speed to keep the engine running at 2300 r/min (rpm). Read the flow gauge and record the reading as test number 7.

3.

Hold the bucket control lever in the DUMP position and adjust the pressure valve on the flowmeter until the pressure gauge indicates 124 bar (1800 psi). Adjust the engine speed to keep the engine running at 2300 r/min (rpm). Read the flow gauge and record the reading as test number 8.

NOTE: Understanding the results of the tests are outlined in the steps below. 4.

Refer to Hydraulic pump - Flow test (A.10.A) Hydraulic pump - Flow test (A.10.A) If the flow indication for a circuit was approximately the same as the flow indication at the same pressure in Test Number 1 of the Hydraulic Pump Flow Test , the circuit is good.

5.

If the flow indication for a circuit was more than 3.8 L/min (one gpm) less than the flow indication at the same pressure in Hydraulic pump - Flow test (A.10.A) Test Number 1, there is leakage in that circuit.

6.

Leakage in the tilt circuits can be caused by any of the following problems: A. Damaged or worn packing in one or both of the tilt cylinders. B. Damaged or worn spool or spool bore in the loader control valve. C. Self-leveling valve (if equipped) is sticking or has worn spools. D. Defective circuit relief valves. E. Inadequate control spool travel.

7.

If the flow indication for every circuit tested was more than 3.8 L/min (one gpm) less than the flow indication at the same pressure in test number. 1, there is leakage at a point common to the entire system. A probable cause is a damaged or worn main relief valve or seals.

84522361 15/06/2011

H.30.C / 4

Index HITCH AND WORKING TOOL - H ARM TOOL ATTACHMENT Tilt - 30.C Relief valve - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Relief valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

H.30.C / 5

84522361 15/06/2011

H.30.C / 6

HITCH AND WORKING TOOL - H SINGLE ARM Lift - 40.B

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

H.40.B / 1

Contents HITCH AND WORKING TOOL - H SINGLE ARM Lift - 40.B

TECHNICAL DATA Accumulator General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Control valve Overview loader lock control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE SINGLE ARM Lift Remove single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 C227

Install single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C227

Remove single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L218, L220, L223, L225, L230, C232, C238

Install single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 L218, L220, L223, L225, L230, C232, C238

SINGLE ARM Lift - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Control valve Remove loader valve extend solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install Loader Valve Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Remove loader valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Install loader valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - Remove bucket valve extend solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Install Bucket Valve Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 L230, C227

Remove bucket valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 L230, C227

Install bucket valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 L230, C227

Remove proportional auxiliary valve extend solenoid on EH machines . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 L230, C227

Install proportional auxiliary valve extend solenoid (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 L230, C227

Remove proportional auxiliary valve retract solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Install proportional auxiliary valve retract solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 84522361 15/06/2011

H.40.B / 2

Remove loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 C227 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

Install loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 C227, C232, C238

Remove loader control valve (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 L213, L215

Install loader control valve (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 L213, L215

Remove proportional auxiliary valve retract solenoid on EH machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Install proportional auxiliary valve extend solenoid (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Remove Proportional aux valve extend solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Install proportional auxiliary valve extend solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Remove Boom position/Bucket position/ Auxiliary position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Install Boom position/Bucket position/ Auxiliary position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Remove Loader port lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Install Loader port lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Ride control valve Install Glide Ride valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Remove Glide Ride valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Relief valve Pressure test Loader Valve Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Cylinder Remove lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 L213, L215, C227

Install lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 L230, C227

Remove lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 L218, L220, L223, L225, L230, C232, C238

Install lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 L218, L220, L223, L225, L230, C232, C238

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Accumulator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 84522361 15/06/2011

H.40.B / 3

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

DIAGNOSTIC SINGLE ARM Lift Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

84522361 15/06/2011

H.40.B / 4

HITCH AND WORKING TOOL - SINGLE ARM Lift

Accumulator - General specification Manufacturer

Parker

Fluid Capacity

750 ml (25.4 US fl oz)

Charge with dry nitrogen

2070 kPa (300.2 psi)

Max operating pressure

27580 kPa (4000.1 psi)

Port

Internal straight thread 3/4-16 UNF - 2B

84522361 15/06/2011

H.40.B / 5

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Overview loader lock control valve On-Road regulations require the loader arm and bucket to be locked in a ‘traveling’ position. To prevent the operator from inadvertently lowering or raising the loader or bucket causing damage to roadway, vehicles or machine. Operator to place bucket and loader in the appropriate position. Operator then switches the loader lock to on position, locking the bucket and loader in the set position. The operator will not be able to move the bucket and loader until the loader lock switch has been turned off. The switch will illuminate when Loader Lock is on. The function is always active when hydraulics are enabled. A Mechanical Machine with Loader Lock on will trigger trouble code 4952. This is expected.

84522361 15/06/2011

H.40.B / 6

HITCH AND WORKING TOOL - SINGLE ARM Lift

SINGLE ARM Lift - Remove single lift arm C227

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

1.

2.

3.

If applicable, disconnect case drain hose (1).

93107451A

1

931002065

2

931002066

3

Label and disconnect auxiliary hydraulic hoses and cap open ports

Label and disconnect bucket cylinder hoses and cap open ports.

84522361 15/06/2011

H.40.B / 7

HITCH AND WORKING TOOL - SINGLE ARM Lift

4.

5.

6.

7.

Disconnect electrical connections (1).

931001737

4

931001620A

5

931001618

6

931001616

7

Raise and support the lift arm (1) using appropriate straps.

Remove rod end snap rings (1).

Remove rod end pins and washers (1).

NOTE: Right hand side has lock out

84522361 15/06/2011

H.40.B / 8

HITCH AND WORKING TOOL - SINGLE ARM Lift

8.

9.

Lower cylinders down

931001625

8

931002067A

9

lower the lift arm and reposition the lifting device and straps.

NOTICE: If equipped with an electrical harness, remove harness now. 10.

11.

Remove left hand side and right hand lift arm retaining bolts (1).

931001622

10

931002068

11

Remove left hand side and right hand side lift arm pins (1).

84522361 15/06/2011

H.40.B / 9

HITCH AND WORKING TOOL - SINGLE ARM Lift

12.

Remove lift arm.

931001624A

Next operation: SINGLE ARM Lift - Install single lift arm (H.40.B)

84522361 15/06/2011

H.40.B / 10

12

HITCH AND WORKING TOOL - SINGLE ARM Lift

SINGLE ARM Lift - Install single lift arm C227

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Prior operation: SINGLE ARM Lift - Remove single lift arm (H.40.B) 1.

2.

3.

Using appropriate lifting device and straps raise lift arm into proper location on the unit.

931001624A

1

931002068

2

931001622

3

Install left hand side and right hand side lift arm pins (1).

Install left hand side and right hand side lift arm retaining bolts (1).

84522361 15/06/2011

H.40.B / 11

HITCH AND WORKING TOOL - SINGLE ARM Lift

4.

5.

6.

Reposition lifting device and straps and raise lift arm (1).

931001620A

4

931001625

5

931001616

6

931001618

7

Raise cylinders (1) up.

Insert cylinders into arm and secure with rod end pins and washers (1).

NOTE: Right hand side has lock out.

7.

Install rod end snap rings (1).

84522361 15/06/2011

H.40.B / 12

HITCH AND WORKING TOOL - SINGLE ARM Lift

8.

9.

Connect bucket cylinder hoses.

931002066

8

931002065

9

Connect auxiliary hydraulic hoses (1).

84522361 15/06/2011

H.40.B / 13

HITCH AND WORKING TOOL - SINGLE ARM Lift

SINGLE ARM Lift - Remove single lift arm L218, L220, L223, L225, L230, C232, C238

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

1.

2.

3.

If applicable, disconnect the case drain hose (1).

93107451A

1

931002065

2

931002066

3

Label and disconnect auxiliary hydraulic hoses (1) and cap open ports.

Label and disconnect bucket cylinder hoses and cap open ports.

84522361 15/06/2011

H.40.B / 14

HITCH AND WORKING TOOL - SINGLE ARM Lift

4.

5.

6.

7.

Label and disconnect quick detach hoses and cap open ports.

931001736

4

931001737

5

80112878

6

931001618

7

Unplug electrical connection (1).

Support the lift arm (1) using the appropriate straps and hoist.

Remove lift cylinder rod end snap rings (1).

84522361 15/06/2011

H.40.B / 15

HITCH AND WORKING TOOL - SINGLE ARM Lift

8.

Remove rod end pins and washers (1).

NOTE: Right hand side has lock out.

9.

10.

11.

931001616

8

931001625

9

Lower cylinders down.

Lower lift arm and reposition lifting device and straps.

931002067A

10

931001622

11

Remove left hand side and right hand side lift arm retaining bolts (1).

84522361 15/06/2011

H.40.B / 16

HITCH AND WORKING TOOL - SINGLE ARM Lift

12.

13.

Remove left hand side and right hand side lift arm pins (1).

931002068

12

931001624A

13

Remove lift arm.

Next operation: SINGLE ARM Lift - Install single lift arm (H.40.B)

84522361 15/06/2011

H.40.B / 17

HITCH AND WORKING TOOL - SINGLE ARM Lift

SINGLE ARM Lift - Install single lift arm L218, L220, L223, L225, L230, C232, C238

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Prior operation: SINGLE ARM Lift - Remove single lift arm (H.40.B) 1.

2.

3.

Using appropriate lifting device and straps raise lift arm (1) into mounting location.

80112878

1

931002068

2

931001622

3

Install left hand side and right hand side lift arm pins (1).

Install left hand side and right hand side lift arm retaining bolts (1).

84522361 15/06/2011

H.40.B / 18

HITCH AND WORKING TOOL - SINGLE ARM Lift

4.

5.

6.

Reposition lifting device and straps and raise lift arm (1).

931001620A

4

931001625

5

931001616

6

931001618

7

Raise cylinders (1) up.

Insert cylinders into arm and secure with rod end pins and washers (1).

NOTE: Right hand side has lock out.

7.

Install rod end snap rings (1).

84522361 15/06/2011

H.40.B / 19

HITCH AND WORKING TOOL - SINGLE ARM Lift

8.

9.

10.

11.

Connect electrical connections (1).

931001737

8

931001736

9

Connect quick connect hoses.

Connect bucket cylinder hoses.

931002066

10

931002065

11

Connect auxiliary hydraulic hoses (1).

84522361 15/06/2011

H.40.B / 20

HITCH AND WORKING TOOL - SINGLE ARM Lift

SINGLE ARM Lift - Pressure test 1.

If the hydraulic oil is not at operating temperature run the engine at full throttle and hold the bucket control lever in the ROLLBACK position for 30 seconds. Then return the bucket control lever to NEUTRAL for 15 seconds. Repeat this cycle until the temperature of the oil is at least 52°C (125°F).

2.

Disconnect the hydraulic lines from the implement controller where they connect to the loader control valve.

3.

Connect a 4,137 kPa (41 bar) (600 psi) pressure gauges to pilot line at spool ends.

4.

Start the engine and run at high idle. Read the pressure gauge and record the EH Pressure reading at high idle. Pressure should be 0 bar (0.0 psi) with lever in neutral.

5.

Move the implement controller lever (1) to raise the loader control arms. Read the pressure gauge and record the EH pressure reading.

6.

Move the implement controller lever (1) to lower the loader control arms. Read the pressure gauge and record the EH pressure reading.

7.

Move the implement controller lever (1) to tilt the loader bucket. Read the pressure gauge and record the EH pressure reading.

8.

Move the implement controller lever (1) to dump the loader bucket. Read the pressure gauge and record the EH pressure reading.

9.

The pressure readings should vary from 0 kPa (0 bar) (0 psi) to 2482 kPa (24.8 bar) (360 psi) at high idle for a given angle on the implement control handle.

10.

If the pressure readings are correct, the test is complete. If the pressure readings are not correct, repair or replace the charge/hydrostatic pump assembly or the loader control valve.

84522361 15/06/2011

H.40.B / 21

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Remove loader valve extend solenoid Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

4.

Raise the boom (1) and tilt cab forward (2).

931002289

1

931001711

2

931001711

3

Locate loader valve extend solenoid Y-009 (1) on the loader valve block (2) on the right hand side of machine.

Disconnect connector X-28 (1) from the loader valve extend solenoid Y-009 (2).

Remove the two bolts securing the loader valve extend solenoid Y-009 on the loader valve block.

Next operation: Control valve - Install Loader Valve Extend Solenoid (H.40.B)

84522361 15/06/2011

H.40.B / 22

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Install Loader Valve Extend Solenoid Prior operation: Control valve - Remove loader valve extend solenoid (H.40.B) 1.

Insert loader valve extend solenoid Y-009 into the loader valve block.

2.

Insert the two retaining screws into loader valve extend solenoid Y-009. Tighten to 5 N·m (3.7 lb ft).

3.

Reconnect connector X-28 to the loader valve extend solenoid Y-009.

Next operation: Tilt system - Lower (E.34.A)

84522361 15/06/2011

H.40.B / 23

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Remove loader valve retract solenoid Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

4.

Raise the boom (1) and tilt cab forward (2).

931002289

1

931001711

2

931001711

3

Locate loader valve retract solenoid Y-007 (1) next to the loader valve extend solenoid Y-009 (2). These are located on the loader valve block (3) on right hand side of machine.

Disconnect connector X-27 (1) from the loader valve retract solenoid Y-007 (2). Loader valve retract solenoid Y-007 is next to the loader valve extend solenoid Y-009 (3).

Remove the two bolts securing the loader valve retract solenoid Y-007 on the loader valve block.

Next operation: Control valve - Install loader valve retract solenoid (H.40.B)

84522361 15/06/2011

H.40.B / 24

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Install loader valve retract solenoid Prior operation: Control valve - Remove loader valve retract solenoid (H.40.B) 1.

Insert loader valve retract solenoid Y-007 into the loader valve block.

2.

Insert the two retaining screws into loader valve retract solenoid Y-007. Tighten to 5 N·m (3.7 lb ft).

3.

Reconnect connector X-27 to the loader valve retract solenoid Y-007.

Next operation: Tilt system - Lower (E.34.A)

84522361 15/06/2011

H.40.B / 25

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Remove bucket valve extend solenoid Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

4.

Raise the boom (1) and tilt cab forward (2).

93107498

1

931001711

2

931001711

3

Locate bucket valve extend solenoid Y-006 (1) on the loader valve block (2) on the right hand side of machine.

Disconnect connector X-26 (1) from the bucket valve extend solenoid Y-006 (2).

Remove the two bolts securing the bucket valve extend solenoid Y-006 on the loader valve block.

Next operation: Control valve - Install Bucket Valve Extend Solenoid (H.20.B)

84522361 15/06/2011

H.40.B / 26

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Install Bucket Valve Extend Solenoid L230, C227

Prior operation: Control valve - Remove bucket valve extend solenoid (H.40.B) 1.

Insert bucket valve extend solenoid Y-006 into the loader valve block.

2.

Insert the two retaining screws into bucket valve extend solenoid Y-006. Tighten to 5 N·m (3.7 lb ft).

3.

Reconnect connector X-26 to the bucket valve extend solenoid Y-006.

Next operation: Tilt system - Lower (E.34.A)

84522361 15/06/2011

H.40.B / 27

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Remove bucket valve retract solenoid L230, C227

Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

4.

Raise the boom (1) and tilt cab forward (2).

931002289

1

931001711

2

931001711

3

Locate bucket valve retract solenoid Y-003 (1) on the loader valve block (2) on the right hand side of machine.

Disconnect connector X-25 (1) from the bucket valve retract solenoid Y-003 (2).

Remove the two bolts securing the bucket valve retract solenoid Y-003 on the loader valve block.

Next operation: Control valve - Install bucket valve retract solenoid (H.20.B)

84522361 15/06/2011

H.40.B / 28

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Install bucket valve retract solenoid L230, C227

Prior operation: Control valve - Remove bucket valve retract solenoid (H.20.B) 1.

Insert bucket valve retract solenoid Y-003 into the loader valve block.

2.

Insert the two retaining screws into bucket valve retract solenoid Y-003. Tighten to 5 N·m (3.7 lb ft).

3.

Reconnect connector X-25 to the bucket valve retract solenoid Y-003.

Next operation: Tilt system - Lower (E.34.A)

84522361 15/06/2011

H.40.B / 29

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Remove proportional auxiliary valve extend solenoid on EH machines L230, C227

Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

4.

Raise the boom (1) and tilt cab forward (2).

931002289

1

931001711

2

931001711

3

Locate proportional auxiliary valve extend solenoid (1) on the loader valve block (2) next to the proportional aux retract solenoid (3) on the right hand side of machine.

Disconnect connector (1) from the proportional auxiliary valve extend solenoid (2).

Remove the two bolts securing the proportional auxiliary valve extend solenoid on the loader valve block.

Next operation: Control valve - Install proportional auxiliary valve extend solenoid (EH) (H.20.B)

84522361 15/06/2011

H.40.B / 30

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Install proportional auxiliary valve extend solenoid (EH) L230, C227

Prior operation: Control valve - Remove proportional auxiliary valve extend solenoid on EH machines (H.20.B) 1.

2.

3.

Insert proportional auxiliary valve extend solenoid into the loader valve block .

931001711

1

931001711

2

20111502

3

Insert the two retaining screws into proportional auxiliary valve extend solenoid. Tighten to 5 N·m (3.7 lb ft).

Reconnect connector (1) to the proportional auxiliary valve extend solenoid.

Next operation: Tilt system - Lower (E.34.A)

84522361 15/06/2011

H.40.B / 31

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Remove proportional auxiliary valve retract solenoid (Mechanical) Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

Raise the boom (1) and tilt cab forward (2).

931002289

1

931002092B

2

Locate proportional auxiliary valve retract solenoid (1) on the loader valve block (2).

84522361 15/06/2011

H.40.B / 32

HITCH AND WORKING TOOL - SINGLE ARM Lift

3.

Disconnect connector (1) from the proportional auxiliary valve retract solenoid (2).

931002095

4.

Remove the two bolts securing the proportional auxiliary valve retract solenoid on the loader valve block.

Next operation: Control valve - Install proportional auxiliary valve retract solenoid (Mechanical) (H.40.B)

84522361 15/06/2011

H.40.B / 33

3

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Install proportional auxiliary valve retract solenoid (Mechanical) 1.

2.

3.

Insert the proportional auxiliary valve retract solenoid (1).

931002095

1

931002095

2

931002095

3

Connect connector (1) to the proportional auxiliary valve retract solenoid (2).

Insert the two retaining screws (1) into proportional auxiliary valve retract solenoid. Tighten to 5 N·m (3.7 lb ft).

84522361 15/06/2011

H.40.B / 34

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Remove loader control valve C227 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

Prior operation: Bucket - Remove (J.20.B). Prior operation: Tilt system - Tilt (E.34.A). 1.

2.

3.

Remove drain plug (1) and drain hydraulic oil reservoir.

931001657

1

931001708

2

931002075

3

Label and disconnect the rear solenoid connections (1).

Label and disconnect both linkages or six solenoid connections from valve, depending on your configuration.

84522361 15/06/2011

H.40.B / 35

HITCH AND WORKING TOOL - SINGLE ARM Lift

4.

5.

6.

931001709

4

931001709

5

931001713

6

931001715

7

Label and disconnect the two front solenoid connections (1).

Label and disconnect six hydraulic tubes (1) from control valve and cap open ports.

Label and disconnect drain hoses (1) from control valve.

84522361 15/06/2011

H.40.B / 36

HITCH AND WORKING TOOL - SINGLE ARM Lift

7.

8.

9.

10.

Label and disconnect two hoses (1) and one tube (2) from top of control valve.

931001710

8

931001714

9

Disconnect hydraulic tubes (1) located at bottom of valve block.

Disconnect hydraulic hoses (1) from solenoid block.

931001711

10

931001718

11

Remove the three valve mounting bolts (1) (one shown).

84522361 15/06/2011

H.40.B / 37

HITCH AND WORKING TOOL - SINGLE ARM Lift

11.

Remove loader valve.

931001719

Next operation: Control valve - Install loader control valve (H.40.B)

84522361 15/06/2011

H.40.B / 38

12

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Install loader control valve C227, C232, C238

Prior operation: Control valve - Remove loader control valve (H.40.B) 1.

2.

Position loader valve in proper location on skid steer chassis.

931002096B

1

931002096B

2

Install the three loader valve mounting bolts (1) (one shown) securing the valve to the chassis.

84522361 15/06/2011

H.40.B / 39

HITCH AND WORKING TOOL - SINGLE ARM Lift

3.

Connect electrical connections (1), (2), and (3).

NOTE: The electrical connection in picture 931002094a is located on the top right hand side of chain case

4.

5.

931002094 B

3

931002095B

4

931002093B

5

931002092B

6

Connect control linkage (1) and (2).

Connect hydraulic tube (1) and hydraulic hose (2) to solenoid block.

84522361 15/06/2011

H.40.B / 40

HITCH AND WORKING TOOL - SINGLE ARM Lift

6.

7.

8.

Install hydraulic tube (1) located at the bottom of valve block.

931002091C

7

931002090A

8

931002089A

9

Connect hoses (1) and (2) and tube (3) to the top of control valve.

Connect the two drain hoses (1) to control valve.

84522361 15/06/2011

H.40.B / 41

HITCH AND WORKING TOOL - SINGLE ARM Lift

9.

10.

Connect the six hydraulic tubes to control valve in the correct ports, as shown.

931002088A

10

931001657

11

Install hydraulic oil reservoir drain plug (1) and fill to the correct level.

Next operation: Tilt system - Lower (E.34.A). Next operation: Bucket - Install (J.20.B).

84522361 15/06/2011

H.40.B / 42

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Remove loader control valve (EH) L213, L215

Prior operation: Bucket - Remove (J.20.B). Prior operation: Tilt system - Tilt (E.34.A). 1.

Apply vacuum to hydraulic reservoir. Use CAS10192 and CAS1871.

2.

Label and disconnect the four rear solenoid connections (1).

3.

4.

931001708

1

931001709

2

931001713

3

Label and disconnect the six front solenoid connections (1).

Label and disconnect six hydraulic tubes (1) from control valve and cap open ports.

84522361 15/06/2011

H.40.B / 43

HITCH AND WORKING TOOL - SINGLE ARM Lift

5.

6.

7.

8.

Label and disconnect drain hoses (1) from control valve.

931001715

4

931001710

5

931001714

6

931001711

7

Label and disconnect two hoses (1) and one tube (2) from top of control valve.

Disconnect hydraulic tubes (1) located at bottom of valve block.

Disconnect hydraulic hoses (1) from solenoid block.

84522361 15/06/2011

H.40.B / 44

HITCH AND WORKING TOOL - SINGLE ARM Lift

9.

10.

Remove the three valve mounting bolts (1) (one shown).

931001718

8

931001719

9

Remove loader valve.

Next operation: Control valve - Install loader control valve (EH) (H.40.B)

84522361 15/06/2011

H.40.B / 45

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Install loader control valve (EH) L213, L215

Prior operation: Control valve - Remove loader control valve (EH) (H.40.B) 1.

2.

3.

Position the control valve into the machine mounting location.

931001719

1

931001718

2

931001711

3

Install the three valve mounting bolts (1) (one shown).

Connect hydraulic hoses (1) to solenoid block.

84522361 15/06/2011

H.40.B / 46

HITCH AND WORKING TOOL - SINGLE ARM Lift

4.

5.

6.

7.

Connect hydraulic tubes (1) located at the bottom of valve block.

931001714

4

931001710

5

931001715

6

931001713

7

Connect two hoses (1) and one tube (2) to the top of control valve.

Connect the two drain hoses (1) to control valve.

Connect the six hydraulic tubes (1) to there correct ports on the control valve.

84522361 15/06/2011

H.40.B / 47

HITCH AND WORKING TOOL - SINGLE ARM Lift

8.

9.

Connect the six front solenoid connections (1).

931001709

8

931001708

9

Connect rear solenoid connections (1).

Next operation: Tilt system - Lower (E.34.A). Next operation: Bucket - Remove (J.20.B).

84522361 15/06/2011

H.40.B / 48

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Remove proportional auxiliary valve retract solenoid on EH machines L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

3.

4.

Raise the boom (1) and tilt cab forward (2).

931002289

1

931001711

2

931001711

3

Locate proportional auxiliary valve retract solenoid (3) on the loader valve block (2) next to the proportional aux extend solenoid (1) on the right hand side of machine.

Disconnect connector (1) from the proportional auxiliary valve retract solenoid (2).

Remove the two bolts securing the proportional auxiliary valve extend solenoid on the loader valve block.

84522361 15/06/2011

H.40.B / 49

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Install proportional auxiliary valve extend solenoid (EH) L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

3.

Insert proportional auxiliary valve retract solenoid into the loader valve block .

931001711

1

931001711

2

20111502

3

Insert the two retaining screws into proportional auxiliary valve retract solenoid. Tighten to 5 N·m (3.7 lb ft).

Reconnect connector (1) to the proportional auxiliary valve retract solenoid.

84522361 15/06/2011

H.40.B / 50

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Remove Proportional aux valve extend solenoid (Mechanical) L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

Raise the boom (1) and tilt cab forward (2).

931002289

1

931002092B

2

Locate proportional auxiliary valve extend solenoid (1) on the loader valve block (2).

84522361 15/06/2011

H.40.B / 51

HITCH AND WORKING TOOL - SINGLE ARM Lift

3.

Disconnect connector (1) from the proportional auxiliary valve extend solenoid (2).

931002095

4.

Remove the two bolts securing the proportional auxiliary valve extend solenoid on the loader valve block.

84522361 15/06/2011

H.40.B / 52

3

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Install proportional auxiliary valve extend solenoid (Mechanical) L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

1.

2.

3.

Insert the proportional auxiliary valve extend solenoid (1).

931002095

1

931002095

2

931002095

3

Connect connector (1) to the proportional auxiliary valve extend solenoid (2).

Insert the two retaining screws (1) into proportional auxiliary valve extend solenoid. Tighten to 5 N·m (3.7 lb ft).

84522361 15/06/2011

H.40.B / 53

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Remove Boom position/Bucket position/ Auxiliary position L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

3.

Locate the control valve (1) on the right hand side of the machine.

20111502

1

20111502

2

Locate the different position sensors. The boom position sensor (1), bucket position sensor (2), and auxiliary sensor (3) are located here.

Remove the nut holding the sensor. Pull sensor off.

84522361 15/06/2011

H.40.B / 54

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Install Boom position/Bucket position/ Auxiliary position L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

1.

2.

Insert the sensor onto the loader control valve. The boom position sensor (1), bucket position sensor (2), and auxiliary sensor (3) are located here.

20111502

1

20111502

2

Thread nut (1) onto sensor. Tighten to proper torque.

84522361 15/06/2011

H.40.B / 55

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Remove Loader port lock solenoid 1.

2.

3.

4.

Locate the loader control valve (1) on the right hand side of the machine.

931002090

1

931002090

2

931002090

3

Disconnect the electrical connector (1) from the solenoid.

Remove the nut from the solenoid (1).

Remove the solenoid.

84522361 15/06/2011

H.40.B / 56

HITCH AND WORKING TOOL - SINGLE ARM Lift

Control valve - Install Loader port lock solenoid 1.

2.

Place solenoid onto the loader control valve. Thread nut (1) onto valve body.

931002090

1

931002090

2

Connect the electrical connector (1) to the solenoid.

84522361 15/06/2011

H.40.B / 57

HITCH AND WORKING TOOL - SINGLE ARM Lift

Ride control valve - Install Glide Ride valve Prior operation: Ride control valve - Remove Glide Ride valve (H.40.B) 1.

2.

3.

4.

Locate valve (1) position on body.

931001804

1

931001698

2

931001698

3

931001693

4

Install mounting hardware (1).

Connect upper tubes (1).

Connect the lower hydraulic tube (1).

84522361 15/06/2011

H.40.B / 58

HITCH AND WORKING TOOL - SINGLE ARM Lift

5.

6.

7.

Connect drain hose (1) and secure with hose clamp.

931001693

5

931001696

6

Connect valve electrical connection (1).

Disengage cab lock and tilt cab down. See Tilt system - Lower (E.34.A)

84522361 15/06/2011

H.40.B / 59

HITCH AND WORKING TOOL - SINGLE ARM Lift

Ride control valve - Remove Glide Ride valve Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

4.

Locate ride control valve (1) on the skid steer chassis.

931001804

1

931001696

2

931001693

3

931001693

4

Disconnect the valve electrical connection (1).

Remove hose clamp and disconnect drain hose (1) and cap open ports.

Disconnect the lower hydraulic tube (1) and cap open ports.

84522361 15/06/2011

H.40.B / 60

HITCH AND WORKING TOOL - SINGLE ARM Lift

5.

6.

7.

Disconnect the two upper hydraulic tubes (1) and cap open ports.

931001698

5

931001698

6

931001700

7

Remove mounting hardware (1).

Remove valve.

Next operation: Ride control valve - Install Glide Ride valve (H.40.B)

84522361 15/06/2011

H.40.B / 61

HITCH AND WORKING TOOL - SINGLE ARM Lift

Relief valve - Pressure test Loader Valve Relief Valve PRIMARY HYDRAULIC POWER SYSTEM - Special tools (A.10.A) 1.

Park the machine on a level surface.

2.

Lower all attachments to the floor.

3.

Stop the engine.

4.

Move the control levers in all directions to release any circuit pressure.

5.

The best way to connect the hand pump is directly to the control valve. Disconnect the tube from the port of the control valve and connect the hand pump to the port. By connecting directly to the control valve, you avoid the possibility of a bad reading because of cylinder movement.

6.

Remove all dirt and grease from the connecting point.

7.

Connect the hose of the hand pump to the connecting point, but do not tighten the connection.

8.

Make sure that the hand pump is filled with oil. The temperature of the oil must be at least 21°C (70°F).

9.

Operate the hand pump to fill the hose of the hand pump with oil. Then tighten the connections.

10.

Operate the hand pump and read the pressure gauge. Record the highest indication. Check the pressure several times to make sure that the indications are correct.

11.

Compare the indication with the specification Pump - General specification (C.20.F). If the indication is not correct, replace the circuit relief valve.

NOTE: The circuit relief valves for the loader circuit are not adjustable and must be replaced if they do not meet the specification. 12.

Repeat this test after installing a new circuit relief valve.

84522361 15/06/2011

H.40.B / 62

HITCH AND WORKING TOOL - SINGLE ARM Lift

Relief valve - Flow test Prior operation: Relief valve - Flow test (A.10.A) Relief valve - Flow test (A.10.A) 1.

Start the engine and run the engine at 2300 r/min (rpm).

2.

Hold the lift control lever in the LIFT position and adjust the pressure valve on the flowmeter until the pressure gauge indicates 124 bar (1800 psi). Adjust the engine speed to keep the engine running at 2300 r/min (rpm). Read the flow gauge and record the reading as test number 9.

3.

Hold the lift control lever in the LOWER position and adjust the pressure valve on the flowmeter until the pressure gauge indicates 124 bar (1800 psi). Adjust the engine speed to keep the engine running at 2300 r/min (rpm). Read the flow gauge and record the reading as test number 10.

NOTE: Understanding the results of the tests are outlined in the steps below. 4.

Refer to Hydraulic pump - Flow test (A.10.A) Hydraulic pump - Flow test (A.10.A) If the flow indication for a circuit was approximately the same as the flow indication at the same pressure in Test Number 1 of the Hydraulic Pump Flow Test , the circuit is good.

5.

If the flow indication for a circuit was more than 3.8 L/min (one gpm) less than the flow indication at the same pressure in Hydraulic pump - Flow test (A.10.A) Test Number 1, there is leakage in that circuit.

6.

Leakage in the lift circuits can be caused by any of the following problems: A. Damaged or worn packing in one or both of the lift cylinders. B. Damaged or worn spool or spool bore in the loader control valve. C. Defective circuit relief valves. D. Inadequate control spool travel.

7.

If the flow indication for every circuit tested was more than 3.8 L/min (one gpm) less than the flow indication at the same pressure in test number. 1, there is leakage at a point common to the entire system. A probable cause is a damaged or worn main relief valve or seals.

84522361 15/06/2011

H.40.B / 63

HITCH AND WORKING TOOL - SINGLE ARM Lift

Cylinder - Remove lift arm cylinder L213, L215, C227

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Prior operation: Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A) 1.

2.

3.

Label and disconnect cylinder hoses (1) and cap open ports

931001628

1

931001621

2

931001616

3

Remove lift cylinder rod end snap rings (1) from boom arm.

Remove rod end pins and washers (1).

84522361 15/06/2011

H.40.B / 64

HITCH AND WORKING TOOL - SINGLE ARM Lift

4.

5.

6.

7.

Lower cylinders (1) down.

931001625

4

931001629

5

931001630

6

931001632

7

Remove lock nut (1) and pin retaining bolt (2) on both sides of the lift arm.

Remove rod end pins and washers from both sides of the lift arm.

Remove cylinders

Next operation: Cylinder - Install lift arm cylinder (H.20.B)

84522361 15/06/2011

H.40.B / 65

HITCH AND WORKING TOOL - SINGLE ARM Lift

Cylinder - Install lift arm cylinder L230, C227

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Prior operation: Cylinder - Remove lift arm cylinder (H.40.B) 1.

Lubricate the rod end pins, (1), with LOCTITE® 767 ANTI-SEIZE lubricant.

2.

Install the cylinder onto the skid steer.

3.

Install pin retaining bolt (1), and locknut, (2).

4.

Torque the upper pivot pin hardware to 38 Nm ( 28 lb ft.

5.

931001630

1

931001629

2

931001616

3

Install the rod end pins and washers (1) through the lift arms and cylinder end.

84522361 15/06/2011

H.40.B / 66

HITCH AND WORKING TOOL - SINGLE ARM Lift

6.

Install rod end snap rings (1).

7.

Install the hydraulic cylinder hoses (1), and position to prevent contact with other components, fenders, etc. Tighten hose fittings to standard torque.

8.

Lower the lift arm. Tilt system - Tilt To secure the lift arm in the raised position on radial lift machines. (E.34.A)

9.

Start the skid steer and cycle the boom several times to remove trapped air from the system and check the cylinder for leaks.

84522361 15/06/2011

H.40.B / 67

931001618

4

931001628

5

HITCH AND WORKING TOOL - SINGLE ARM Lift

Cylinder - Remove lift arm cylinder L218, L220, L223, L225, L230, C232, C238

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

1.

2.

3.

Label and disconnect cylinder hoses (1) and cap open ports

93112872

1

93112873

2

931001616

3

Remove lift cylinder rod end pin (2) and retaining bolt (1) and nut (3) from boom arm.

Remove rod end pins and washers (1).

84522361 15/06/2011

H.40.B / 68

HITCH AND WORKING TOOL - SINGLE ARM Lift

4.

5.

6.

7.

Lower cylinders (1) down.

93112875

4

93112874

5

931001630

6

931001632

7

Remove lock nut (1) and pin retaining bolt (2) on frame.

Remove rod end pins and washers from both sides of the frame.

Remove cylinders

Next operation: Cylinder - Install lift arm cylinder (H.40.B)

84522361 15/06/2011

H.40.B / 69

HITCH AND WORKING TOOL - SINGLE ARM Lift

Cylinder - Install lift arm cylinder L218, L220, L223, L225, L230, C232, C238

WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Prior operation: Cylinder - Remove lift arm cylinder (H.40.B) 1.

Lubricate the rod end pins, (1), with LOCTITE® 767 ANTI-SEIZE lubricant.

2.

Install the cylinder onto the skid steer.

3.

Install pin retaining bolt (1), and locknut, (2).

4.

Torque the upper pivot pin hardware to 38 Nm ( 28 lb ft.

5.

931001630

1

931001629

2

931001616

3

Install the rod end pins and washers (1) through the lift arms and cylinder end.

84522361 15/06/2011

H.40.B / 70

HITCH AND WORKING TOOL - SINGLE ARM Lift

6.

Install rod end snap rings (1).

7.

Install the hydraulic cylinder hoses (1), and position to prevent contact with other components, fenders, etc. Tighten hose fittings to standard torque.

8.

Lower the lift arm

9.

Start the skid steer and cycle the boom several times to remove trapped air from the system and check the cylinder for leaks.

84522361 15/06/2011

H.40.B / 71

931001618

4

931001628

5

HITCH AND WORKING TOOL - SINGLE ARM Lift

Cylinder - Disassemble Prior operation: Cylinder - Remove (H.40.B) 1.

Clean the outside of the cylinder. If the hoses were removed from the cylinder, remove the hoses.

2.

Fasten the tube (1) in a vise, or other holding equipment can be used. Be careful not to damage the tube.

3.

Loosen the gland (5) in the tube with a gland wrench.

4.

To prevent damage to the tube, pull the piston rod (3) straight out of the tube.

5.

Fasten the piston rod end in a vise. To prevent damage to the piston rod, place a padded support below the piston rod near the piston.

6.

Loosen and remove the nut that connects the piston on the piston rod.

7.

Remove the piston (6) from the piston rod.

8.

Remove and discard the seal (11), wear ring (13) and backup ring (12) from the piston.

9.

Remove and discard the O-ring (9), backup ring (10), seals (8), and wiper (7) from the gland (5).

20111254

(1) Tube (2) Bushing (3) Piston Rod

(4) Bushing (5) Packing gland (6) Piston

1

(7) Wiper (8) Seal (kit) (9) O-ring 84522361 15/06/2011

H.40.B / 72

(10) Backup ring (11) Seal (12) Backup Ring

(13) Wear ring (14) Nut (15) Rod end

HITCH AND WORKING TOOL - SINGLE ARM Lift

Cylinder - Assemble Prior operation: Cylinder - Disassemble (H.40.B)

20111254

1. 2. 3. 4. 5. 6.

Tube Bushing Piston Rod Bushing Packing gland Piston

1

7. Wiper 8. Seal (kit) 9. O-ring 10. Backup ring 11. Seal 12. Backup Ring

13. Wear ring 14. Nut 15. Rod end

NOTE: If a new gland is being installed, put the part number of the cylinder on the new gland. 1.

Before assembly, lubricate the rod (3) and the cylinder bore with hydraulic oil.

2.

Lubricate a new seal (8) with clean hydraulic oil. Insert the new seal into the gland so the lips are toward the small end of the gland.

3.

Lubricate a new wiper (7) with hydraulic oil. Insert the new wiper into the gland so the lips are toward the large end of the gland.

4.

Lubricate a new backup ring (10) with clean hydraulic oil. Insert the new backup ring into the groove on the outside of the gland so the flat side is toward the large end of the gland.

5.

Lubricate a new O-ring (9) with clean hydraulic oil. Insert the O-ring into the groove and onto the backup ring on the outside of the gland.

6.

Fasten the piston rod end (15) in a vise. 84522361 15/06/2011

H.40.B / 73

HITCH AND WORKING TOOL - SINGLE ARM Lift

7.

Remove any marks or sharp edges on the chamfered end of the piston rod.

8.

Lubricate the bore of the gland with clean hydraulic oil.

9.

Push the gland onto the piston rod. If the gland will not slide easily onto the piston rod, use a soft hammer to drive the gland onto the piston rod.

10.

To prevent damage to the piston rod, place a support below and near the end of the piston rod. Use a shop cloth between the support and the piston rod.

11.

Install the piston (6) onto the end of the piston rod.

12.

Clean the threads on the end of the piston rod and the threads of the nut using Loctite cleaning solvent. Allow all the parts to dry. Apply 1/2 in of LOCTITE® 242 onto the threads of the piston rod 1/4 in from the open end of the piston rod.

NOTE: Do not apply LOCTITE® 242 to the first 1/4 in of the piston rod threads. 13.

Install the nut (14).

14.

Tighten the nut to a torque of 365 - 469 Nm ( 270 346 lb ft). A torque multiplier can be used to tighten the nut.

15.

Lubricate a new backup ring (12) with clean hydraulic oil. Slide the backup ring into the center groove on the outside of the piston.

16.

Lubricate a new seal (11) with clean hydraulic oil. Slide the new seal onto the backup ring on the outside of the piston.

17.

Lubricate a new wear ring (13) with clean hydraulic oil. Slide the new wear ring into the end groove on the opposite end of the piston.

18.

Lubricate the inside of the tube and the piston with clean hydraulic oil. Use a piston ring compression tool to hold the new wear ring in place.

19.

Push the tube straight onto the piston.

20.

Start the tube onto the piston rod assembly. Push the tube onto the piston rod until the compression tool is clear of the piston rod. Be careful not to damage the wear ring and the seal.

21.

When the piston is in the smooth part of the tube, start the gland into the tube.

22.

Lubricate the new O-ring on the gland with clean hydraulic oil.

23.

Tighten the gland to the torque of 407 Nm ± 68 Nm ( 300 lb ft ± 50 lb ft).

24.

If hoses were removed with the cylinder, install new O-rings, if equipped, on the hose fittings. Lubricate the new O-rings with clean hydraulic oil and install the hoses.

84522361 15/06/2011

H.40.B / 74

HITCH AND WORKING TOOL - SINGLE ARM Lift

Accumulator - Remove WARNING Pressurized system! DO NOT attempt to disassemble any accumulator until the nitrogen charge is properly discharged. Failure to comply could result in death or serious injury. W0974A

Prior operation: Accumulator - Discharging (H.40.B)

bs04d011

(1) - Hose connection (2) - Accumulator

1

Ride Control Accumulator (3) - Clamps (4) - Electrical harness

84522361 15/06/2011

H.40.B / 75

(5) - Ride control valve

HITCH AND WORKING TOOL - SINGLE ARM Lift

1.

Remove the cap CAS1871 from the hydraulic reservoir.

2.

Connect a vacuum pump CAS10192 to the hydraulic reservoir.

3.

Start the vacuum pump. Refer to Reservoir - Apply vacuum (A.10.A)

4.

Loosen and remove the hydraulic hose connection (1) from the accumulator (2). Install a plug in the hose and a cap on the fitting.

5.

Stop the vacuum pump.

6.

Loosen and remove the two clamps (3) which mount the accumulator (2) to the chassis. Remove the accumulator from the chassis.

bs04d012

2

Ride Control Component Location (1) - Ride control accumulator

(2) - Ride control valve

Next operation: Accumulator - Disassemble (H.40.B) or Accumulator - Install (H.40.B)

84522361 15/06/2011

H.40.B / 76

HITCH AND WORKING TOOL - SINGLE ARM Lift

Accumulator - Install Prior operation: Accumulator - Remove (H.40.B) 1.

Install the accumulator (2) into the chassis mounting location.

2.

Install the clamps (3) around the accumulator (2) and tighten the clamps (3).

3.

Start the vacuum pump.

4.

Remove the plug from the hose and the cap from the fitting.

5.

Install the hydraulic hose connection (1) onto the accumulator (2). Tighten the hydraulic hose connection (1).

6.

Stop the vacuum pump. Remove vacuum pump from reservoir.

bs04d011

(1) - Hose connection (2) - Accumulator

1

Ride Control Accumulator (3) - Clamps (4) - Electrical harness

7.

Stop the vacuum pump.

8.

Remove the vacuum pump from the hydraulic reservoir. Install the filler cap on the reservoir.

9.

Follow the procedure for Accumulator Charging with dry nitrogen. Accumulator - Charging (H.40.B)

10.

Start and run the engine at low idle for 2 to 5 minutes and check for any leaks. 84522361 15/06/2011

H.40.B / 77

(5) - Ride control valve

HITCH AND WORKING TOOL - SINGLE ARM Lift

11.

Stop the engine.

12.

Check the hydraulic oil level in the reservoir and add hydraulic oil as required. Reservoir - Filling (A.10.A)

84522361 15/06/2011

H.40.B / 78

HITCH AND WORKING TOOL - SINGLE ARM Lift

84522361 15/06/2011

H.40.B / 79

HITCH AND WORKING TOOL - SINGLE ARM Lift

Accumulator - Assemble

BS96H068

1. 2. 3. 4.

Tube Gland with gas valve Piston Seal

5. 6. 7. 8.

Quad ring O-ring Backup ring (if used) Cap screw

1

9. Guard 10. Gas valve assembly 11. Cap 12. Valve core

Prior operation: Accumulator - Disassemble (H.40.B) 1.

Slide one new seal (4), on one end of the piston.

2.

Slide one new quad ring (5) into the middle groove of the piston.

3.

Slide one new seal (4) on the other end of the piston.

4.

Lubricate the bore of the tube (1) and the piston (3) with clean hydraulic oil.

NOTE: The piston must be installed slowly to prevent damage to the threads on the quad ring.

84522361 15/06/2011

H.40.B / 80

13. Body 14. Gland without gas valve

HITCH AND WORKING TOOL - SINGLE ARM Lift

5.

Start the piston (3) into the gas valve end of the tube (1). A soft hammer and wood block may be used to drive the piston farther into the tube. Carefully drive the piston at least 2 in ( 51 mm) into the tube. Keep pressure against the piston when driving the piston into the tube, to prevent damage to the quad ring (5). Follow the same procedure for the non-gas valve end of the tube.

6.

If used, install a new back ring (7) on the gland (2). Make sure the backup ring is installed. Follow the same procedure for the non-gas valve end of the tube.

7.

Install the O-ring (6) next to the backup ring (7). If a backup ring is not used, install an O-ring in the groove on the gland. Follow the same procedure for the non-gas valve end of the tube.

BS04D006

8.

Lubricate the O-ring (6) and the backup ring (7) with clean hydraulic oil. Start the gland (2) into the tube (1). Follow the same procedure for the non-gas valve (14) end of the tube.

9.

Fasten the tube (1) in the vise. Tighten the gland (2). Follow the same procedure for the non-gas valve end of the tube

10.

Install a new O-ring (6)on the body (13)of the gas valve assembly (10).

11.

Install the valve core (12) in the body (13).

12.

Lubricate the O-ring (6) with clean hydraulic oil. Install and tighten the gas valve assembly (10)in the gland (2).

13.

Install the cap (11).

14.

Charge the accumulator with dry nitrogen. Please refer to Accumulator - Charging (H.40.B)

15.

Install the guard (9) and cap screws (8).

Next operation: Accumulator - Install (H.40.B)

84522361 15/06/2011

H.40.B / 81

2

HITCH AND WORKING TOOL - SINGLE ARM Lift

Accumulator - Disassemble Prior operation: Accumulator - Remove (H.40.B) 1.

Fasten the accumulator tube (1) in a vise with soft jaws. Be careful not to damage the tube.

NOTICE: The gland with the gas valve must be removed first. 2.

Loosen and remove the glands (2) or (14) from each end of the tube.

3.

Use a rod and push the piston (3) out of the gas valve end of the tube.

4.

Remove and discard the seals (4) and quad ring (5) from the piston.

5.

Remove and discard the O-rings (6) and if used, the backup ring (7) from the glands.

6.

Loosen and remove the cap screws (8) and guard (9).

7.

Loosen and remove the gas valve assembly (10).

8.

Remove the O-ring (6), cap (11), and valve core (12) from the body (13).

BS96H067

1. 2. 3. 4.

Tube Gland with gas valve Piston Seal

5. 6. 7. 8.

Quad ring O-ring Backup ring (if used) Cap screw

1

9. Guard 10. Gas valve assembly 11. Cap 12. Valve core

84522361 15/06/2011

H.40.B / 82

13. Body 14. Gland without gas valve

HITCH AND WORKING TOOL - SINGLE ARM Lift

Next operation: Accumulator - Visual inspection (H.40.B)

84522361 15/06/2011

H.40.B / 83

HITCH AND WORKING TOOL - SINGLE ARM Lift

Accumulator - Discharging NOTICE: Do not attempt to disassemble any accumulator until the nitrogen charge is properly discharged. NOTICE: To help prevent equipment damage, the low pressure gauge (3) must be shut "Off" during high pressure ( 150 psi/ 10 bar and above) applications.

934477A

(A) - Regulator (B)

(C) - Low pressure gauge (D)

1.

Use the accumulator charging kit CAS10899 to discharge the accumulator. The tool must be disconnected from the nitrogen tank.

2.

Close valves (B), (C) and (D).

3.

Adjust the regulator (A) to the minimum pressure setting by turning the knob counterclockwise.

4.

Turn the T-handle on valve (F) fully out.

5.

Remove the guard and cap from the accumulator charging stem.

6.

Connect valve (F) to the stem on the accumulator.

7.

Turn the T-handle inward on valve (F) to engage the pin in the valve stem.

8.

Open valve (D). Check the charge pressure on gauge (E).

9.

Partially open valve (B) to discharge the accumulator. The accumulator charge will bleed down through the regulator.

10.

Once the accumulator is fully discharged, disconnect valve (F) from the accumulator stem.

1

(E) (F)

84522361 15/06/2011

H.40.B / 84

(G) - To nitrogen tank (H) - To accumulator

HITCH AND WORKING TOOL - SINGLE ARM Lift

Accumulator - Charging SPECIAL TOOLS

BS06M002

1

380001676 Nitrogen Regulator Valve

BS06M003-01

2

380001390 Accumulator Charging Hose NOTE: Check the pressure in the accumulator according to the instructions in this section. Keep the nitrogen charging kit connected to the accumulator.

84522361 15/06/2011

H.40.B / 85

HITCH AND WORKING TOOL - SINGLE ARM Lift

BT09C458

3

Nitrogen Charging Kit

BT09B037-01

4

Accumulator located on the right side of machine behind side skirt. NOTE: Do not expose the accumulator to temperatures above 120°F (49°C). A charged accumulator contains nitrogen compressed to 1600 PSI (11 032 kPa). High heat will cause the safety plug to blow out of the accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed. M407

Charging Accumulator with Nitrogen WARNING Explosion hazard! Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an explosion. Failure to comply could result in death or serious injury. W0975A

84522361 15/06/2011

H.40.B / 86

HITCH AND WORKING TOOL - SINGLE ARM Lift

WARNING Explosion hazard! Do not expose the accumulator to temperatures above 120°F (49°C). A charged accumulator contains nitrogen compressed to 110 bar (1600 PSI). High heat will cause the safety plug to blow out of the accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed. Failure to comply could result in death or serious injury. W0977C

NOTICE: The four valves A, D, and E must be in the positions noted in the procedure before connecting the Nitrogen Accumulator Charging Kit to the machine or nitrogen tank refer to image 3. 1.

Close the shutoff valve (D) by turning it all the way to the left (counterclockwise).

2.

Close the gauge valve (E) by turning it all the way to the right (clockwise).

3.

Connect the charging gauges to the nitrogen supply tank, open the supply tank valve.

4.

Slowly turn valve (D) clockwise while watching the pressure gauge (B). Stop turning valve (D) when the needle on gauge (B) reaches 10 bar (145 psi).

NOTE: If the needle goes over the needed pressure, quickly open and close valve (E) and check the pressure again. The charging kit is now ready to be installed on the accumulator. 5.

Remove the cap from the accumulator.

6.

Loosen the sealing plug with an Allen wrench.

7.

Back off the needle valve (A) on the accumulator end of the charging hose by turning it counterclockwise to the maximum position. This prevents nitrogen from escaping from the accumulator when the charging hose is attached to the accumulator gas charging valve.

8.

Install the charging hose fitting onto the accumulator.

9.

Tighten the needle valve by turning it clockwise. Slowly open the gauge valve (E) and observe the reading on the gauge. This reading is the nitrogen pressure level inside the accumulator.

10.

Fill the accumulator to a charge pressure of 20.7 22.4 bar (300 - 325 psi).

11.

Close valve (E) by turning to the right (clockwise). After a few minutes open valve (E) and check the accumulator for leakage.

12.

Back off the needle valve (A) on accumulator end of the charging hose by turning it counterclockwise the maximum amount. This will prevent nitrogen from escaping from the accumulator as the hose is removed.

13.

Close the valve on the nitrogen supply tank.

14.

Adjust the regulator (D) to the minimum pressure setting by turning the knob counterclockwise.

15.

Slowly remove the charging hose from the accumulator pressure valve. 84522361 15/06/2011

H.40.B / 87

HITCH AND WORKING TOOL - SINGLE ARM Lift

NOTE: A small amount of nitrogen will escape when disconnecting the hose. 16.

Install the cap on the accumulator, torque to 1.13 N·m (10 lb in).

NOTE: A small amount of nitrogen will escape when disconnecting the hose.

84522361 15/06/2011

H.40.B / 88

HITCH AND WORKING TOOL - SINGLE ARM Lift

84522361 15/06/2011

H.40.B / 89

HITCH AND WORKING TOOL - SINGLE ARM Lift

Accumulator - Visual inspection

BS96H067

1. 2. 3. 4.

Tube Gland with gas valve Piston Seal

5. 6. 7. 8.

Quad ring O-ring Backup ring (if used) Cap screw

1

9. Guard 10. Gas valve assembly 11. Cap 12. Valve core

Prior operation: Accumulator - Disassemble (H.40.B) 1.

Clean all parts in cleaning solvent.

2.

Illuminate the inside of the tube (1). Inspect the inside of the tube for deep grooves or other damage. If the tube is damaged, replace with a new tube or cylinder.

84522361 15/06/2011

H.40.B / 90

13. Body 14. Gland without gas valve

HITCH AND WORKING TOOL - SINGLE ARM Lift

3.

In a rotary motion, use an emery cloth with medium grit to remove small scratches on the piston (3), glands (2) and (14), and tube (1).

4.

Inspect the glands (2) and (14), for rust or corrosion. Clean and remove the rust or corrosion from the gland.

5.

Inspect the piston (3). Check to see if it is worn or damaged. If the piston is worn or damaged, replace with a new accumulator.

6.

Inspect the gland ends of the tube (1) for sharp edges. Remove the sharp edges. Sharp edges can damage the seals (4), quad ring (5), and O-rings (6).

Next operation: Accumulator - Assemble (H.40.B)

84522361 15/06/2011

H.40.B / 91

HITCH AND WORKING TOOL - SINGLE ARM Lift

Accumulator - Pressure test

BS04D004

1.

Ensure that the oil side of the accumulator is completely discharged.

2.

Put the ride control switch in the "On" position.

3.

Lower the loader to the floor. Put the loader control lever in the "Float" position.

4.

Stop the engine. Put the key in the "On" position.

5.

Move the loader control lever in all directions to release any pressure in the hydraulic circuits. Put the loader control lever in the "Float" position.

6.

Find the right and left solenoid valves for the ride control system. Find the pin in the coil end of the solenoid. Depress the pin in the solenoid valves with a soft pin (such as a welding rod) to release any pressure in the loader lift circuit.

7.

Leave the ride control switch and key switch in the "On" postion.

8.

Leave the loader control lever in the "Float" position.

9.

Close the valves (B) and (C) on the nitrogen charging kit.

10.

Turn the stem out of valve (F) until the stem stops.

11.

Remove the cap screws and guard from the accumulator.

12.

Remove the cap from the valve stem on the accumulator.

13.

Connect valve (F) to the valve stem.

14.

Make sure that valve (D) is open.

1

84522361 15/06/2011

H.40.B / 92

HITCH AND WORKING TOOL - SINGLE ARM Lift

15.

Turn the stem into valve (F) and read the pressure on gauge (E).

16.

The pressure must be 275 - 325 psi ( 1897 - 2241 kPa, 19 - 23 bar). If the pressure is too low, charge the accumulator with dry nitrogen.

84522361 15/06/2011

H.40.B / 93

HITCH AND WORKING TOOL - SINGLE ARM Lift

SINGLE ARM Lift - Troubleshooting Problem Incorrect or No Loader Function

Possible Cause Correction 1. Check to ensure the cab door is fully A. Is there still a problem? closed. No: Troubleshooting complete. Yes: Go to Step 2. 2. Check the cab door switch (If equipped A. Check power to and from the cab door with cab door). switch. B. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 3. 3. Check the Implement Controller inter- A. Check power to and from the Implement lock valve power/function. Controller interlock valve. Repair as required. B. Check the Implement Controller interlock valve function. Repair or replace as required. C. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 4. 4. Check the charge pressure. A. Do - Checking the Charge Pressure/ Flow. Refer to Charge pump - Pressure test (A.10.A) for the procedure. B. Charge pressure OK? Stroke the control lever. A 20 psi or greater drop indicates a leaky servo. Repair as required. C. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 5. 5. Check the pilot pressure from the Im- Go to step 6. plement Controller to the Loader Control Valve. 6. Do Check 1 - Checking the Pilot Pres- A. Is there still a problem? sure. No: Troubleshooting complete. Refer to SINGLE ARM Lift - Pressure test Yes: Go to Step 8. (H.40.B) 8. Check the loader control valve function. A. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 9. 9. Repair or replace the loader control valve.

84522361 15/06/2011

H.40.B / 94

Index HITCH AND WORKING TOOL - H SINGLE ARM Lift - 40.B Accumulator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Accumulator - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Accumulator - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Accumulator - Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Accumulator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Accumulator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Accumulator - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Accumulator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Accumulator - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Control valve - Remove bucket valve extend solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Control valve - Install Boom position/Bucket position/ Auxiliary position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control valve - Install Bucket Valve Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 L230, C227

Control valve - Install Loader Valve Extend Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Control valve - Install Loader port lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Control valve - Install bucket valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 L230, C227

Control valve - Install loader control valve (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 L213, L215

Control valve - Install loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 C227, C232, C238

Control valve - Install loader valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Control valve - Install proportional auxiliary valve extend solenoid (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 L230, C227

Control valve - Install proportional auxiliary valve extend solenoid (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control valve - Install proportional auxiliary valve extend solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Control valve - Install proportional auxiliary valve retract solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Control valve - Overview loader lock control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Control valve - Remove Boom position/Bucket position/ Auxiliary position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Control valve - Remove Loader port lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Control valve - Remove Proportional aux valve extend solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 L213 Mechanical hydraulic controls, L215 Mechanical hydraulic controls, L218 Mechanical hydraulic controls, L220 Mechanical hydraulic controls, L223 Mechanical hydraulic controls, L225 Mechanical hydraulic controls, L230 Mechanical hydraulic controls

Control valve - Remove bucket valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 L230, C227

Control valve - Remove loader control valve (EH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 L213, L215

Control valve - Remove loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 C227 Mechanical hydraulic controls, C232 Mechanical hydraulic controls, C238 Mechanical hydraulic controls

Control valve - Remove loader valve extend solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

84522361 15/06/2011

H.40.B / 95

Control valve - Remove loader valve retract solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Control valve - Remove proportional auxiliary valve extend solenoid on EH machines . . . . . . . . . . . . . . . . . . . . . . 30 L230, C227

Control valve - Remove proportional auxiliary valve retract solenoid (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Control valve - Remove proportional auxiliary valve retract solenoid on EH machines . . . . . . . . . . . . . . . . . . . . . . 49 L218 Electro hydraulic controls, L220 Electro hydraulic controls, L223 Electro hydraulic controls, L225 Electro hydraulic controls, L230 Electro hydraulic controls, C227 Electro hydraulic controls, C232 Electro hydraulic controls, C238 Electro hydraulic controls

Cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Cylinder - Install lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 L230, C227

Cylinder - Install lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 L218, L220, L223, L225, L230, C232, C238

Cylinder - Remove lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 L213, L215, C227

Cylinder - Remove lift arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 L218, L220, L223, L225, L230, C232, C238

Relief valve - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Relief valve - Pressure test Loader Valve Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Ride control valve - Install Glide Ride valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Ride control valve - Remove Glide Ride valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 SINGLE ARM Lift - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 SINGLE ARM Lift - Install single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C227

SINGLE ARM Lift - Install single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 L218, L220, L223, L225, L230, C232, C238

SINGLE ARM Lift - Remove single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 C227

SINGLE ARM Lift - Remove single lift arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L218, L220, L223, L225, L230, C232, C238

SINGLE ARM Lift - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

84522361 15/06/2011

H.40.B / 96

HITCH AND WORKING TOOL - H SINGLE ARM TOOL ATTACHMENT Tilt - 50.C

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

H.50.C / 1

Contents HITCH AND WORKING TOOL - H SINGLE ARM TOOL ATTACHMENT Tilt - 50.C

DIAGNOSTIC SINGLE ARM TOOL ATTACHMENT Tilt Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

H.50.C / 2

HITCH AND WORKING TOOL - SINGLE ARM TOOL ATTACHMENT Tilt

SINGLE ARM TOOL ATTACHMENT Tilt - Troubleshooting Problem Incorrect or No Loader Function

Possible Cause Correction 1. Check to ensure the cab door is fully A. Is there still a problem? closed. No: Troubleshooting complete. Yes: Go to Step 2. 2. Check the cab door switch (If equipped A. Check power to and from the cab door with cab door). switch. B. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 3. 3. Check the Implement Controller inter- A. Check power to and from the Implement lock valve power/function. Controller interlock valve. Repair as required. B. Check the Implement Controller interlock valve function. Repair or replace as required. C. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 4. 4. Check the charge pressure. A. Do - Checking the Charge Pressure/ Flow. Refer to Charge pump - Pressure test (A.10.A) for the procedure. B. Charge pressure OK? Stroke the control lever. A 20 psi or greater drop indicates a leaky servo. Repair as required. C. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 5. 5. Check the pilot pressure from the Im- Go to step 6. plement Controller to the Loader Control Valve. 6. Do Check 1 - Checking the Pilot Pres- A. Is there still a problem? sure. No: Troubleshooting complete. Refer to SINGLE ARM Lift - Pressure test Yes: Go to Step 7. (H.40.B) 7. If the pressure readings are correct, the test is complete. If the pressure readings are not correct, repair or replace the charge/hydrostatic pump assembly or the loader control valve. 8. Check the loader control valve function. A. Is there still a problem? No: Troubleshooting complete. Yes: Go to Step 9. 9. Repair or replace the loader control valve.

84522361 15/06/2011

H.50.C / 3

Index HITCH AND WORKING TOOL - H SINGLE ARM TOOL ATTACHMENT Tilt - 50.C SINGLE ARM TOOL ATTACHMENT Tilt - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

H.50.C / 4

84522361 15/06/2011

H.50.C / 5

New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

84522361 15/06/2011 EN

SERVICE MANUAL EXCAVATING AND LANDSCAPING

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

J

Contents EXCAVATING AND LANDSCAPING - J

DIGGING Non-articulated digging tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.20.B C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

CARRYING Unarticulated tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.50.B C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

COUPLING Mechanical coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.80.B C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

COUPLING Hydraulic coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.80.C C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

J

EXCAVATING AND LANDSCAPING - J DIGGING Non-articulated digging tools - 20.B

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

J.20.B / 1

Contents EXCAVATING AND LANDSCAPING - J DIGGING Non-articulated digging tools - 20.B

SERVICE Bucket Remove - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remove - Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install - Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

84522361 15/06/2011

J.20.B / 2

EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools

Bucket - Remove - Mechanical 1.

2.

3.

4.

Position loader on flat surface.

93106896

1

931002056

2

931001679

3

931002057

4

Pull up on locking handles (1) to disengage pins.

Start engine.

Tilt face plate (2) down to disengage.

84522361 15/06/2011

J.20.B / 3

EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools

5.

6.

Lower lift arm (3).

931002057

5

931002058

6

Reverse skid steer to remove bucket.

84522361 15/06/2011

J.20.B / 4

EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools

Bucket - Install 1.

2.

3.

4.

Start engine.

931001679

1

931002058

2

931002057

3

931002057

4

Lower lift arm (1) and tilt faceplate (2) down before inserting faceplate into saddles.

Slowly raise lift arm (1) ensuring face plate is seated in the saddles (3).

Tilt face plate (2) up to engage.

84522361 15/06/2011

J.20.B / 5

EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools

5.

Push down on locking handles (4) to secure bucket.

931002056

84522361 15/06/2011

J.20.B / 6

5

EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools

Bucket - Remove - Hydraulic 1.

2.

3.

Position loader on a flat surface.

9310748611

1

931002111

2

931002112

3

931007524

4

Start engine.

Unlock the pins (1) then use the electronic controls (2) to retract quick release cylinders.

84522361 15/06/2011

J.20.B / 7

EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools

4.

5.

6.

Tilt face plate (3) down to disengage.

931002057

5

931002057

6

931002058

7

Lower lift arm (4).

Remove bucket.

84522361 15/06/2011

J.20.B / 8

EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools

Bucket - Install - Hydraulic 1.

2.

3.

4.

Start engine.

931002111

1

931002058

2

931002057

3

931002057

4

Lower lift arm (1) and tilt faceplate down (2) before inserting into saddles (3).

Slowly raise lift arm (1) ensuring faceplate seats into saddles.

Tilt face plate up to engage.

84522361 15/06/2011

J.20.B / 9

EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools

5.

6.

Use electronic controls (4) on the right hand side joystick to engage quick release cylinders.

931007524

5

931002112

6

Lock the pins in place using the lock control (5) on the left hand side column.

84522361 15/06/2011

J.20.B / 10

Index EXCAVATING AND LANDSCAPING - J DIGGING Non-articulated digging tools - 20.B Bucket - Install - Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Bucket - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bucket - Remove - Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bucket - Remove - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84522361 15/06/2011

J.20.B / 11

84522361 15/06/2011

J.20.B / 12

EXCAVATING AND LANDSCAPING - J CARRYING Unarticulated tools - 50.B

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

J.50.B / 1

Contents EXCAVATING AND LANDSCAPING - J CARRYING Unarticulated tools - 50.B

TECHNICAL DATA Tool Bucket - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Tool Cutting edge - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84522361 15/06/2011

J.50.B / 2

EXCAVATING AND LANDSCAPING - CARRYING Unarticulated tools

Tool Bucket - General specification

BT97G325

1. 10 mm ( 3/8 in) fillet (weld twice 1 root pass 1 cover pass) 2. 6 mm ( 1/4 in) fillet (weld 4 times)

1

3. 6 mm ( 1/4 in) groove 6 mm ( 1/4 in) fillet (weld twice-wrap ends)

84522361 15/06/2011

J.50.B / 3

EXCAVATING AND LANDSCAPING - CARRYING Unarticulated tools

Tool Cutting edge - Replace 1.

Cut or grind the old cutting edge from the bucket floor and sides. Remove all old weld and foreign material from the welding area.

SH88030

2.

Straighten the bucket floor and sides if required.

3.

Thoroughly clean the area where the new cutting edge will be welded.

4.

Use dry AWS-E7018 low hydrogen electrodes or either of the following equivalent low hydrogen wire feed electrodes: Gas metal arc welding (C0² or argon C0²) AWS-E70S6 or flux cored arc welding AWSE70T1.

5.

Preheat the parts to be welded (both tack and final welds) to a minimum of 400ºF (204ºC). The preheat temperature must be throughout the entire thickness of the parts joined, and at least 51 mm ( 2 in) back from the joint. Maintain preheat throughout the entire welding operation.

NOTE: This is a hardened steel edge. If not preheated, the cutting edge may later crack during use. 6.

Tack weld the preheated parts starting at the center of the bucket and working toward the outside ends.

7.

Finish welding the preheated parts starting at the center of the front edge of the bucket floor and working toward the outside ends. Repeat this operation at the back side of the cutting edge to bucket floor.

8.

Do not remove the bucket from the welding environment until the weld and metal temperature drops to the ambient temperature. Do not force the cooling rate of the welds and material.

9.

Follow the same welding procedure for welding the side cutting edges and bottom wear plates to the bucket.

10.

Bolt On Cutting Edge Replacement: Loosen and remove the bolts from the cutting edge.

11.

Remove the cutting edge from the bucket.

12.

Install new cutting edge on the bucket. Install new bolts and tighten the bolts.

13.

Dirt Tooth Kit Installation

14.

Bucket Dirt Tooth Kit

84522361 15/06/2011

J.50.B / 4

1

EXCAVATING AND LANDSCAPING - CARRYING Unarticulated tools

15.

The dirt tooth kit consists of six teeth that are welded to the bucket cutting edge as indicated at (1). The teeth are used to break up the material when rough digging conditions are experienced. This will make it easier to fill the bucket. The teeth are intended to be used only on dirt and foundry or low-profile buckets.

16.

Tooth Point Replacement

17.

The points of the teeth are a replaceable "pin-on" design and can be obtained from Parts.

18.

To replace the "pin-on" points, use a punch that just fits into the pin hole, (1), and drive the old retaining pin from the shank.

19.

Place the new point over the shank and insert the retaining pin into the hole, (1). With a punch that contacts both sides of the metal part of the retaining pin, drive the pin until it is centered in the shank.

SH88032

2

SH88033

3

SH88034

4

NOTE: If the punch or driver is too small and just contacts the rubber center of the retaining pin, the pin will be damaged and will not retain the point.

20.

Tooth Location and Installation

21.

The bucket should be flat on the floor when placing and welding the teeth to maintain good weld points, (1).

NOTICE: Remove the bucket from the loader while welding teeth to prevent damage to the loader electrical system. 22.

Slide the replaceable points in place but do not attach with the steel/rubber pins as the rubber may be damaged during the welding process.

84522361 15/06/2011

J.50.B / 5

EXCAVATING AND LANDSCAPING - CARRYING Unarticulated tools

23.

24.

Locate the teeth on the bucket edge as indicated.

bs04e165

5

bs04f076

6

SH88036

7

bs04e166

8

Bucket Tooth Spacing

NOTE: Position the teeth at these spacings, then re-center if necessary for equal spacing.

25.

Welds are high carbon steel (tooth) to high carbon steel (bucket). Use welding rods marked 7018 or some comparable rod. Weld on both sides of the tooth from the back of the tooth towards the replaceable point at (1). Stop welding 13 mm ( 1/2 in) from the cutting edge as noted at (2). Weld along the back of the tooth at (3). A minimum 5 mm ( 3/16 in) fillet weld is required for this application.

26.

Weld in the direction shown at (1).

27.

Weld a 5 mm ( 3/16 in) fillet weld along both sides and rear of the tooth at (2), high carbon steel to high carbon steel.

84522361 15/06/2011

J.50.B / 6

Index EXCAVATING AND LANDSCAPING - J CARRYING Unarticulated tools - 50.B Tool Bucket - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tool Cutting edge - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84522361 15/06/2011

J.50.B / 7

84522361 15/06/2011

J.50.B / 8

EXCAVATING AND LANDSCAPING - J COUPLING Mechanical coupling - 80.B

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

J.80.B / 1

Contents EXCAVATING AND LANDSCAPING - J COUPLING Mechanical coupling - 80.B

FUNCTIONAL DATA Connector Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Connector Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

84522361 15/06/2011

J.80.B / 2

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

Connector - Exploded view

bs04e150

(1) (2) (3) (4)

Mounting Plate Left Hand Handle Dust Cap Grease Zerk

1

Mounting Plate (7) Latch Pin (8) Plug (9) Clip (10) Pin 84522361 15/06/2011

J.80.B / 3

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

Pin Bolt Right Hand Handle Pin

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

(5) Plate (6) Spring Pin

Mounting Plate (11) Compression Spring (12) Guide

84522361 15/06/2011

J.80.B / 4

(17) Bushing

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

Connector - Exploded view

BS09C164

(1)Right Hand Handle (2)Left Hand Handle (3)Spacer

1

Mounting Plate (8)Pin (9)Spring Guide Upper (10)Compression Spring 84522361 15/06/2011

J.80.B / 5

(15)Roll Pin (16)Latch Pin (17)Mounting Plate

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

(4)Bolt (5)Lock Washer (6)Washer (7)Bolt

Mounting Plate (11)Pin (Spring Guide Lower) (12)Grease Zerk (13)Left Hand Shield (14)Bolt

84522361 15/06/2011

J.80.B / 6

(18)Right Hand Shield (19)Grease Zerk (20)Bushing (21)Washer

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

Connector - Remove 1.

Remove any attachment from the loader attachment mounting plate.

2.

Lower the boom to the fully lowered position.

3.

Tilt the attachment mounting plate forward until the face is level with the ground.

4.

Remove the cylinder attachment mounting plate pivot pins by removing the pin retaining bolts, (1), and sliding the pins from the mounting plate and cylinders.

ATTENTION: Support the mounting plate during removal to prevent dropping the plate when pins are removed.

19984476

5.

Remove hub caps, (2), from the plate pivots.

6.

Loosen the attachment mounting plate to boom pivot pin hardware, (3). DO NOT remove the bolts at this time.

7.

With a soft-faced sledgehammer, strike the mounting plate pivot area, (4). This will free the tapered pivot pin in the boom link.

8.

Remove the pivot pin retaining hardware and remove the tapered pins.

84522361 15/06/2011

J.80.B / 7

1

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

Connector - Install 1.

Reinstall the boom mounting plate, if removed, by installing the plate pivot taper pins and retaining hardware, (1), Figure 1.

2.

Torque the pivot bolts, (1), to 108 Nm ( 80 lb ft).

NOTE: The tapered pivot pins and retaining hardware must be hammer seated by striking the head of the bolt and pin, and then re-tightening. This step must be repeated until the torque remains constant. 3.

Reinstall hub caps, (2), into the plate pivots.

4.

Extend the attachment mounting plate cylinders until they align with their mounting holes on the attachment mounting plate.

5.

Install the cylinder attachment mounting plate pins through the mounting plate and into the cylinder rod ends. Install the pin retaining hardware, (3), and tighten.

6.

Grease the two boom mounting plate pivot pins and the two cylinder mounting plate pivot pins prior to moving the attachment mounting plate to prevent any damage to the pivot points.

19984476-2

7.

Attachment Plate Over-Center Latch Pins Wear/ Bend, Figure 2.

8.

The loader attachment may become loose at the mounting plate. Inspection of the over-center latch pins part #9822358, shows the pin ends worn and bent, (1).

9.

The over-center pins are NOT heat-treaded. Thus, if an attachment does not fit correctly and hammers against the pins, the pins will wear and bend. New pins and ones used with properly fitted attachments should be straight, as shown at (2).

84522361 15/06/2011

J.80.B / 8

1

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

10.

If worn pins are encountered, the pins must be replaced. Additionally, an inspection of all the customer's attachments must be made to determine the improperly fitted attachments which is causing the pin problem. Usually, an old attachment used on a previous loader can be worn and can be the problem.

bs04e168

11.

Checking Procedure for Buckets and Attachments, Figure 3.

12.

The bucket/attachment does not fit or appears to come loose on the boom faceplate.

13.

The loader boom faceplate is worn or out of height dimensions and/or the bucket latch points are worn or out of dimensions.

14.

Inspection

15.

The loader latching system requires that the faceplate wedge into the attachment. The faceplate must contact the attachment at (1), (2), and (3), and must have clearance between the attachment and faceplate at (4), when the attachment is latched properly.

84522361 15/06/2011

J.80.B / 9

2

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

16.

The latch pins should not extend below the lower plate at (5).

bs04e169

17.

The following are some quick visual checks of the loader faceplate and attachment, Figure 4.

18.

The attachment must have an 850 mm ± 0.8 mm (33-15/32 ± 1/32 inch) center to center latch point, (1), to be compatible with the latch system.

19.

Check the latch pins and levers for proper operation and lubrication. If the latch pins do not move freely, the system will not function properly.

20.

Control levers pivot over center into the lowered latched position.

21.

Latch pins fully extend from the faceplate.

84522361 15/06/2011

J.80.B / 10

3

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

22.

Control levers pivot over center into the raised unlatched position and hold in this position.

SH88054

23.

Loader Faceplace, (5), and Attachment, (6), Engagement

24.

Check the saddle area of the attachment at (1), for interference, weld, debris, etc. to prevent the attaching plate and attachment from seating properly.

25.

The loader latch pin should engage the lower latch plates as shown at (2).

26.

Check for clearance between the faceplate and attachment at (3), minimum 0.8 mm ( 1/32 in) and maximum 9.5 mm ( 3/8 in), with the latch pins fully engaged.

27.

If there is no clearance at (3), the loader faceplate is too short or the distance between the top saddle area and lower latch plates is too great, (2), Figure 6

28.

If the clearancies too great or the latch pins will not engage into the latch plates on the attachment, the loader faceplate is too long or the distance between the top saddle area and lower latch plates is too short, (2), or the latch plates are located incorrectly (1), Figure 6.

29.

When the latch pins are fully engaged, New Holland buckets only, the end of the pin should not extend beyond the lower plate at (4).

30.

If the latch handles do not fully engage, the dimension from the back of the attachment to the rear of the slot in the latch plates is too short at (1), Figure 6.

84522361 15/06/2011

J.80.B / 11

4

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

31.

If the latch pins extend below the lower plate at (4), the dimension from the back of the attachment to the rear of the slot in the latch plate is too long at (1), Figure 6.

bs04e170

32.

Checking Procedure

33.

The following are the procedures used to measure the skid steer faceplate and how to measure the attachment.

34.

Checking the Attachment

35.

Check the placement of the lower latch plates at (1). Measure from the back surface of the attachment to the rear of the latch plate slot at (1): 235.8 mm ± 0.8 mm (1-9/32 ± 1/32 inch).

36.

If this dimension is too short, the slot can be widened by grinding out the slot 1/16 inch maximum or replace the latch plates.

37.

If grinding is required, the rear of the slot must be round square with the top surface of the plate to ensure proper pin engagement, (2), Figure 5.

38.

If the dimension is too long, replace the latch plates.

84522361 15/06/2011

J.80.B / 12

5

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

39.

Check the height of the attachment at (2). Insert a 1/2 x 2 inch hex head cap screw with 1/2 inch standard nut as shown at (3). Measure from the top of the bolt, (4) to the rear of the latch plate slot at (5): 403.2 mm ± 0.8 mm (15-7/8 ± 1/32 inch).

40.

If this dimension is incorrect, the lower latch plates will require replacement.

NOTE: If new latch plates are required, order four plates #86506587 (01 mm, 4 inch slot) through Parts and follow the latch plate installation procedure.

bs04e171

41.

Checking the Loader Faceplate

42.

Check the height, (3), of the loader faceplate from the top of the plate at (1), to the bottom of the plate at (2): 396.9 mm ± 0.8 mm (15-5/8 ± 1/32 inch). To check the faceplate, place a 24 inch square over the top of the plate as shown at (4), and a straightedge at (5).

84522361 15/06/2011

J.80.B / 13

6

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

43.

If the faceplate is not within specifications, the plate will require replacement.

44.

Check the faceplate pods to ensure they are straight with each other and not twisted. Place a straightedge across both pods as shown at (1,) across the front flat surface and at (2) the top of the pods.

45.

If the pods are not straight, the faceplate will require straightening or replacement.

84522361 15/06/2011

J.80.B / 14

bs04e172

7

SH88058

8

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

46.

Check the center dimension between the faceplate pods and the overall outside dimension including the removable plate in the extended position for new buckets on the L865, LX865, LX885, and LX985 faceplates.

47.

Inside Dimension, (1): 647.7 mm ( 25-1/2 in).

48.

Outside Dimension, (2): 1122.4 mm ( 44-3/16 in).

49.

Latch Pin Dimension, (3): 850.1 ± 0.8 mm (33-15/32 ± 1/32 inch).

ATTENTION: Do not cut or grind the loader faceplate to adapt any buckets or other attachments. Do not cut or grind the loader faceplate latch pins. 50.

When attaching unapproved attachments, the latch points on the attachment must meet the correct dimensions and be strong enough to maintain the correct dimensions during operation.

SH88059

84522361 15/06/2011

J.80.B / 15

9

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

Connector - Visual inspection 1.

Mounting Plate Assembly

2.

Inspect the plate, (1), for straightness. If the mounting plate pods are not straight with each other it may be difficult to hook up to attachments. If the mounting plate is not within specifications, replace the assembly.

3.

Inspect the latch pin area for excessive wear, which can result in loose attachments. If the pins, (2), do not slide freely, remove the pins, clean and lubricate.

4.

Inspect the mounting plate pivot pins, (3), and bushings, (4), for wear, which can result in loose attachment to the mounting plate boom cylinders.

5.

Inspect the cylinder pivot pins, (5), for wear. Inspect the pivot pin holes for wear that could cause a sloppy fit. Replace the bushings in the mounting plate or pivot pins, if necessary.

1998482

6.

Latch Handle/Spring Assemblies

7.

Inspect the latch handle pivot holes, (6), for excessive wear and binding in the mounting plate.

8.

Check that the spring, (7), is not bent, damaged, or has broken coils. Replace if necessary.

9.

Latch Pins

10.

Examine the latch pins, (2), for excessive wear and binding in the mounting plate.

11.

Check the tapered area of the pins for wear or chips. Replace if necessary.

12.

Pivot Bushings Replacement

13.

Use a suitable bushing driver and remove the old bushings.

14.

Clean the bushing area to remove any dirt, debris and burrs.

84522361 15/06/2011

J.80.B / 16

1

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

15.

Using a bushing driver, install the new pivot bushings from each end of hole, (1). Drive bushings flush with the outer edge of the hub.

NOTE: There will be a space in the center between the two bushings.

16.

Latch Lever and Spring Repair/Rebuild

17.

Clamp the lower spring guide, (1), in a vise. Turn the step bolt, (2), to remove the lower spring guide from the step bolt and remove spring, (3).

OPS87134

2

19984483

3

19984484

4

ATTENTION: When removing the step bolt, the spring will have some compression pressure. Remove the bolt while applying downward pressure on the bolt.

18.

Remove the upper spring guide, (1), pivot block, (2), and step bolt, (3), from handle, (4).

84522361 15/06/2011

J.80.B / 17

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

Connector - Disassemble 1.

Remove any attachment from the loader attachment mounting plate.

2.

Lower the boom to the lowered position.

3.

Tilt the attachment mounting plate forward until the face is level with the ground.

4.

With an Allen wrench, remove the setscrew, (1) from the backside of the mounting plate for both the left and right sides.

5.

Move the latch handle, (1), to align the groove pin in the setscrew hole, (2). Drive out the groove pin with a hammer and punch. Repeat this procedure on other side.

6.

Remove the latch pin from each side from the bottom of the mounting plate.

7.

Remove the cylinder attachment mounting plate pivot pins to allow access to the latch handle pivot pin snap ring clips.

ATTENTION: Support the mounting plate during removal of the mounting plate pivot pins to prevent dropping the plate down when pins are removed.

84522361 15/06/2011

J.80.B / 18

19984477

1

19984478

2

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

8.

9.

Remove the pin retaining bolts, (1), and slide the pins from the mounting plate and cylinders.

19984476

3

19984479

4

19984480

5

Enter the skid steer. Sitting in the operator's seat with the seat belt buckled, start the loader and retract the attachment mounting plate actuating cylinders, (1), fully to clear the attachment mounting plate, (2).

10.

Remove the retaining ring, (1), from the latch handle pivot pin, (2), from the rear of the mounting plate on the LEFT and RIGHT sides.

11.

Using a punch and hammer drive the latch handle retaining pin, (2), downward and out through the front of the attachment mounting plate on both sides. If there is insufficient ground clearance to fully remove the latch handle pivot pins, lift the attachment mounting plate up as necessary to clear the pins.

84522361 15/06/2011

J.80.B / 19

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

12.

Remove the handle/spring assembly, (1), from the attachment mounting plate on the LEFT and RIGHT sides of the attachment mounting plate.

19984481

84522361 15/06/2011

J.80.B / 20

6

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

Connector - Assemble 1.

Insert the pivot block, (1), and step bolt, (4), into the handle, (2). Install the upper spring guide, (3), onto step bolt (4).

2.

Install spring, (5), over the upper spring guide, (3). Install the lower spring guide, (6), onto step bolt, (4), and tighten.

NOTE: Apply slight pressure to the lower spring guide to compress the spring slightly and start threading the lower guide onto the step bolt.

3.

4.

19984485

1

19984481-1

2

19984486

3

Slide the latch handle/spring assembly, (1), into the mounting plate, pointing the spring down.

Install the handle pivot pin, (1), from the front of the plate and install the snap ring retaining clip, (2). The pivot pins will have a snap ring on both ends of the pins.

NOTE: The handle pivot pin should have one snap ring retaining clip already installed prior to reinstallation in the attachment plate. If the snap ring retaining clip is not present, install the clip prior to pin installation.

5.

Move the latch handle, (1), to align hole with the groove and insert the latch pin with the tapered side towards the loader boom, away from the attachment.

84522361 15/06/2011

J.80.B / 21

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

6.

7.

With a hammer and punch, drive the grooved pin, (2), through the lower spring guide and latch pin.

19984478

4

19984477

5

Reinstall the setscrew, (1).

84522361 15/06/2011

J.80.B / 22

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

Connector - Disassemble 1.

Remove any attachment (bucket etc.) loader attachment mounting plate.

2.

Tilt the mounting plate forward until the face is level with the ground.

3.

Remove the cover plate (1), from the mounting plate.

4.

from the

1

BT09C188

2

BT09C189

3

Moving the latch handle (1), align the groove pin (2), in the setscrew hole (3). Drive out the groove pin with a hammer and punch.

5.

Remove the latch pin (4), from the bottom of the mounting plate.

6.

Remove the latch handle pivot bolt and spacer (5).

7.

Remove the handle spring assembly (1), from the plate.

8.

BT09C187

Repeat the procedure for both the right and left sides.

84522361 15/06/2011

J.80.B / 23

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

Connector - Assemble 1.

Slide the handle spring assembly into the mounting plate at (1), pointing the spring downward.

2.

Install the handle pivot bolt and tighten to standard bolt torque specifications.

3.

Install the latch pin (1), with the tapered side towards the loader boom, away from the attachment.

4.

With a hammer and punch, drive the grooved pin through the lower spring guide and latch pin at (2).

5.

Reinstall the spacer washer and cap screw at (1).

84522361 15/06/2011

J.80.B / 24

BT09C189

1

BT09C059

2

BT09C060

3

EXCAVATING AND LANDSCAPING - COUPLING Mechanical coupling

6.

Reinstall the boom mounting plate if removed. Torque the pivot bolts (1), to 108 N·m (80 lb ft). The tapered pivot pins and retaining hardware must be hammer seated by striking the head of the bolt and pin (2), and recheck torque on the bolt.

NOTE: This Step must be repeated until the torque is maintained.

BT09C185

84522361 15/06/2011

J.80.B / 25

4

Index EXCAVATING AND LANDSCAPING - J COUPLING Mechanical coupling - 80.B Connector - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Connector - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Connector - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Connector - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Connector - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connector - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Connector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Connector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connector - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

84522361 15/06/2011

J.80.B / 26

EXCAVATING AND LANDSCAPING - J COUPLING Hydraulic coupling - 80.C

C227 , C232 , C238 , L213 , L215 , L218 , L220 , L223 , L225 , L230

84522361 15/06/2011

J.80.C / 1

Contents EXCAVATING AND LANDSCAPING - J COUPLING Hydraulic coupling - 80.C

TECHNICAL DATA Control valve General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L218, L220, L223, L225, L230, C227, C232, C238

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 L218, L220, L223, L225, L230, C227, C232, C238

Cylinder General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L218, L220, L223, L225, L230, C227, C232, C238

SERVICE Cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DIAGNOSTIC Electrical control Testing Hydraulic Coupler Switch and Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84522361 15/06/2011

J.80.C / 2

EXCAVATING AND LANDSCAPING - COUPLING Hydraulic coupling

Control valve - General specification L218, L220, L223, L225, L230, C227, C232, C238

Valve Flow Body material Pressure Port size

P/O (Pilot operated) double check 30.3 l/min (8 US gpm) 2024 Aluminum 206.9 bar (3000 psi) 9/16-18 SAE-6

84522361 15/06/2011

J.80.C / 3

EXCAVATING AND LANDSCAPING - COUPLING Hydraulic coupling

Control valve - General specification L218, L220, L223, L225, L230, C227, C232, C238

Valve Solenoid valve configuration Hydraulic requirements: Flow System pressure Relief valve pressure Electrical requirements: Operating voltage Operating temperature range Port size

Coupler 4 way, 2 position direct acting, spool type hydraulic cartridge valve 30.3 l/min (8 US gpm) 210 bar (3045.0 psi) 172 bar (2494.0 psi) 14 V -30 - 107 °C (-22.0 - 224.6 °F) SAE-6

84522361 15/06/2011

J.80.C / 4

EXCAVATING AND LANDSCAPING - COUPLING Hydraulic coupling

Cylinder - General specification L218, L220, L223, L225, L230, C227, C232, C238

Cylinder Collapsed length Extended length Stroke length Tube bore diameter Rod diameter Tube end diameter Rod end diameter Supply port size Return port size Maximum working pressure

Hydraulic coupler 151.9 mm (5.98 in) 199.9 mm (7.87 in) 48.0 mm (1.89 in) 38.1 mm (01.5 in) 19.1 mm (0.750 in) 13.6 mm (0.534 in) 9.6 mm (0.378 in) 7/16-20 UNF-2B 7/16-20 UNF-2B 206.9 bar (3000 psi)

84522361 15/06/2011

J.80.C / 5

EXCAVATING AND LANDSCAPING - COUPLING Hydraulic coupling

Cylinder - Remove Prior operation: Bucket - Remove (J.20.B). NOTE: Never loosen any hydraulic lines without first relieving all pressure in the system. 1.

Remove snap ring.

2.

Remove retaining pin.

3.

Disconnect hydraulic hoses from manifold.

4.

Remove rod end hydraulic hose.

5.

Remove roll pin and bucket locking pin.

6.

Remove cylinder.

84522361 15/06/2011

J.80.C / 6

EXCAVATING AND LANDSCAPING - COUPLING Hydraulic coupling

Cylinder - Install 1.

Lubricate the pivot pins with an antiseize-type lubricant.

2.

Install the cylinder on the skid steer.

3.

Install rod end washers and pins.

4.

Install pin retaining bolts.

5.

Uncap open ports and connect cylinder hoses.

84522361 15/06/2011

J.80.C / 7

EXCAVATING AND LANDSCAPING - COUPLING Hydraulic coupling

Electrical control - Testing Hydraulic Coupler Switch and Solenoid NOTE: Use schematics Wiring harness - Electrical schematic frame 05 (A.30.A) Wiring harness - Electrical schematic frame 06 (A.30.A) Wiring harness - Electrical schematic frame 25 (A.30.A) (EH) Wiring harness - Electrical schematic frame 02 (A.30.A) (Mech) Test Point N° 1 Condition With the ignition on, Check for voltage from ACCESSORY POWER DISTRIBUTION pin E12 and ground.

Expected Result Result 12 V Action Go to test 2

2 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between ACCESSORY POWER DISTRIBUTION pin E12 and connector X-300 pin E. 3 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-300 pin F and ground. 4 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-CPLR pin 1 and connector X-300 pin A. 5 Condition Use ELECTRICAL POWER SYSTEM - Testing General Wire Testing (A.30.A) to check wire condition between connector X-CPLR pin 2 and ground. 6 Condition Disconnect connector X-CPLR from the HYDRAULIC COUPLER SOLENOID Y-013. Check Using a multi-meter, check for resistance between HYDRAULIC COUPLER SOLENOID pins 1 and 2.

Result No wire problems Action Go to test 3

Other Result (Possible Cause) Result 0V Action There is a problem in the DC distribution system upstream of HIGH FLOW / COUPLER FUSE. Action If wire problems are found, repair or replace broken wire 751/ 744 (Orange).

Result No wire problems Action Go to test 4

Action If wire problems are found, repair or replace broken wire 918/ 940/942/1094 (Black).

Result No wire problems Action Go to test 5

Action If wire problems are found, repair or replace broken wire 752 (White).

Result No wire problems Action Go to test 6

Action If wire problems are found, repair or replace broken wire 978/ 1008/1014 (Black).

Result Normal resistance Action The HYDRAULIC COUPLER SWITCH S-009 has failed. Replace the switch

Result 0 Ω or greater than 500 Ω, Action The solenoid has failed. Replace the solenoid.

84522361 15/06/2011

J.80.C / 8

Index EXCAVATING AND LANDSCAPING - J COUPLING Hydraulic coupling - 80.C Control valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 L218, L220, L223, L225, L230, C227, C232, C238

Control valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 L218, L220, L223, L225, L230, C227, C232, C238

Cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L218, L220, L223, L225, L230, C227, C232, C238

Cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical control - Testing Hydraulic Coupler Switch and Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84522361 15/06/2011

J.80.C / 9

New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

84522361 15/06/2011 EN

SPECIAL TOOL INDEX IU

Genuine CAS10162A [Portable Filter Caddy] CAS1871 [Adapter] CAS10192 [Vacuum Pump] CAS1871 [Adapter] CAS10508 [Fitting Kit For Unions] CAS1871 [Adapter] CAS1808 [Flowmeter Fitting Kit] CAS1871 [Adapter] CAS10193 [ Kit For Vacuum Pump] CAS10192 [Vacuum Pump] CAS1871 [Adapter] CAS1871 [Adapter] CAS10192 [Vacuum Pump]

PAGE

PRIMARY HYDRAULIC POWER SYSTEM - Cleaning

A.10.A / 104

PRIMARY HYDRAULIC POWER SYSTEM - Cleaning PRIMARY HYDRAULIC POWER SYSTEM - Cleaning PRIMARY HYDRAULIC POWER SYSTEM - Cleaning PRIMARY HYDRAULIC POWER SYSTEM - Cleaning

A.10.A / 104 A.10.A / 104 A.10.A / 104 A.10.A / 104

PRIMARY HYDRAULIC POWER SYSTEM - Cleaning Relief valve - Pressure test Loader valve main relief

A.10.A / 104 A.10.A / 110

Reservoir - Apply vacuum Reservoir - Apply vacuum

A.10.A / 123 A.10.A / 123

Control valve - Remove loader control valve Control valve - Remove loader control valve Accumulator - Remove Accumulator - Remove

H.40.B H.40.B H.40.B H.40.B

Kit

IU

CAS10899 [Nitrogen Charging Accumulator - Discharging Kit]

15/06/2011

11

/ / / /

43 43 76 76

PAGE H.40.B / 84

New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2011 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

84522361 15/06/2011 EN

NHCE L213 / L215 / L218 / L220 / L223 / L225 / L230 200 Series Skid Steer Loader - Electrohydraulic C227 / C232 / C238 200 Series Compact Track Loader - Electrohydraulic

GROUNDS

BULKHEAD CONNECTION

SHEET 1

SHEET 2

INSTRUMENT CLUSTER

MAIN POWER DISTRIBUTION

ACCESSORY POWER DISTRIBUTION

SHEET 3

SHEET 4

SHEET 5

LEFT HAND CAB CONSOLE

LH AND RH NH CONTROL HANDLE

LAMPS

SHEET 6

SHEET 7

SHEET 8

84526432 ELECTRICAL SCHEMATIC, WORLDWIDE 2011 PRODUCTION—

COMPONENT

ABBREVIATION

CONNECTOR DIODE FUSE LAMP MOTOR RELAY SENSOR/SENDER SPLICE SWITCH WIRE BREAK

X-001 D-001 F-001 E-001 M-001 K-001 B-001 SP-001 B-001 WB-001

SHEET 1 OF 5 SCHEMATIC SYMBOLS COLOR DIODE

FUSE

LAMP

COIL

CHASSIS GROUND (EARTH)

TWISTED WIRES

SPLICE

WIRE SIZE

CONNECTOR I.D.

914-3 BK 18GA

SHT 3 WB-999 CIRCUIT I.D.

CAVITY

C-999-99

WIRE COLOR

BLACK BLUE LIGHT BLUE BLACK/WHITE

MOTOR

WIRE BREAK

ABBREVIATION

WIRE BREAK I.D. WB-999 SHT 3

WIRE BREAK DESTINATION

BK BL LB BK/WH GN LG OR PK VT RD GY TN

GREEN LIGHT GREEN ORANGE PINK VIOLET RED GREY TAN WHITE YELLOW

WH YE

WIRE CHART SIZE

WIRING REFERENCES 18GA

0.5 0.8 1.0 2.0 3.0 5.0 8.0

20 18 16 14 12 10 8

LEGEND INDICATES CONSTANT POWER INDICATES POWER WHEN KEY SWITCH IS ON

SUBSYSTEM DESCRIPTION GROUNDS BULKHEAD CONNECTION INSTRUMENT CLUSTER MAIN POWER DISTRIBUTION ACCESSORY POWER DISTRIBUTION LEFT HAND CAB CONSOLE LH AND RH NH CONTROL HANDLE LAMPS DOOR AND WINDOW ENGINE TYPE CONFIGURATION ENGINE PREHEATING F5C EXT EGR ENGINE ISM ENGINE IGN SWITCH / INDICATORS HYDRAULIC INTERLOCKS / 2ND AUX EU LIGHT ADAPTER HVAC BOOM ROAD LIGHTS RH NH CONTROL HANDLE SEAT RADIO F5C ENGINE KSB COLD START CIRCUIT UJM CONNECTORS LOADER VALVE AND SENSORS BULKHEAD CONNECTION UCM ET PUMP DIAGNOSTIC CONNECTOR MULTIFUNCTION CONNECTORS TELEMATICS DIAGNOSTIC CONNECTOR EHF MULTIFUNCTION JUMPER

SHEET # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

DOOR AND WINDOW

ENGINE TYPE CONFIGURATION

ENGINE PREHEATING

SHEET 9

SHEET 10

SHEET 11

F5C EXT EGR ENGINE

ISM ENGINE

IGNITION SWITCH/INDICATORS

SHEET 12

SHEET 13

SHEET 14

HYDRAULIC INTERLOCKS / 2ND AUX

EU LIGHT ADAPTER

HVAC

SHEET 15

SHEET 16

SHEET 17

84526432 - SHEET 2 OF 5

BOOM ROAD LIGHTS

RH NH CONTROL HANDLE

SHEET 18

SHEET 19

SEAT

RADIO

F5C ENGINE KSB COLD START CIRCUIT

SHEET 20

SHEET 21

SHEET 22

UJM CONNECTORS

LOADER VALVE AND SENSORS

BULKHEAD CONNECTION

SHEET 23

SHEET 24

SHEET 25

NHCE L213 / L215 / L218 / L220 / L223 / L225 / L230 200 Series Skid Steer Loader - Electrohydraulic C227 / C232 / C238 200 Series Compact Track Loader - Electrohydraulic

COMPONENT CONNECTOR DIODE FUSE LAMP MOTOR RELAY SENSOR/SENDER SPLICE SWITCH WIRE BREAK

84526432 ELECTRICAL SCHEMATIC, WORLDWIDE 2011 PRODUCTION—

ABBREVIATION X-001 D-001 F-001 E-001 M-001 K-001 B-001 SP-001 B-001 WB-001

SHEET 3 OF 5 SCHEMATIC SYMBOLS COLOR DIODE

FUSE

LAMP

COIL

CHASSIS GROUND (EARTH)

TWISTED WIRES

SPLICE

WIRE SIZE

CONNECTOR I.D.

914-3 BK 18GA

SHT 3 WB-999 CIRCUIT I.D.

CAVITY

C-999-99

WIRE COLOR

BLACK BLUE LIGHT BLUE BLACK/WHITE

MOTOR

WIRE BREAK

ABBREVIATION

WIRE BREAK I.D. WB-999 SHT 3

WIRE BREAK DESTINATION

GREEN LIGHT GREEN ORANGE PINK VIOLET RED GREY TAN

BK BL LB BK/WH GN LG OR PK VT RD GY TN

WHITE YELLOW

WH YE

WIRE CHART SIZE

WIRING REFERENCES 0.5 0.8 1.0 2.0 3.0 5.0 8.0

18GA

20 18 16 14 12 10 8

LEGEND INDICATES CONSTANT POWER INDICATES POWER WHEN KEY SWITCH IS ON

SUBSYSTEM DESCRIPTION GROUNDS BULKHEAD CONNECTION INSTRUMENT CLUSTER MAIN POWER DISTRIBUTION ACCESSORY POWER DISTRIBUTION LEFT HAND CAB CONSOLE LH AND RH NH CONTROL HANDLE LAMPS DOOR AND WINDOW ENGINE TYPE CONFIGURATION ENGINE PREHEATING F5C EXT EGR ENGINE ISM ENGINE IGN SWITCH / INDICATORS HYDRAULIC INTERLOCKS / 2ND AUX EU LIGHT ADAPTER HVAC BOOM ROAD LIGHTS RH NH CONTROL HANDLE SEAT RADIO F5C ENGINE KSB COLD START CIRCUIT UJM CONNECTORS LOADER VALVE AND SENSORS BULKHEAD CONNECTION UCM ET PUMP DIAGNOSTIC CONNECTOR MULTIFUNCTION CONNECTORS TELEMATICS DIAGNOSTIC CONNECTOR EHF MULTIFUNCTION JUMPER

SHEET # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

UCM

ET PUMP

DIAGNOSTIC CONNECTOR

SHEET 26

SHEET 27

SHEET 28

MULTIFUNCTION CONNECTORS

TELEMATICS

DIAGNOSTIC CONNECTOR

SHEET 29

SHEET 30

SHEET 31

EHF

MULTIFUNCTION JUMPER

SHEET 32

SHEET 33

84526432 - SHEET 4 OF 5

1 20 12

2

High Flow Solenoid Below Hydrostatic Pump - If equipped

Self Level Valve Solenoid 19

12 3

Mechanical Brake Control Valve If equipped 20 12

4

21 12

5 12 6

Glide Control 18

EH Hydrostatic Pump - If equipped - Swash Plate Sensors, located on bottom of pump

17

12 7

6

93107498

View A

2 speed Brake Valve - If equipped 93107448

View B

12 8

10

11 9

15

Aux Extend and Retract Solenoid (For Mechanical machines)

14 12 16

13

12

EH Loader Control (Tag along) - If equipped

PWM Controller (For Mechanical machines)

LEGEND Electrical Component Identification View A 1. Self Level Solenoid 2. High Flow Solenoid 3. Left Hand Reverse Solenoid 4. Right Hand Reverse Solenoid 5. Right Hand Forward Solenoid 6. Left Hand Forward Solenoid 7. Boom Position Sensor 8. Bucket Position Sensor 9. Aux Position Sensor 10. Boom Retract Solenoid 11. Boom Extend Solenoid 12. Bucket Retract Solenoid 13. Aux Reverse Solenoid 14. Aux Forward Solenoid 15. Bucket Extend Solenoid 16. Aux PWM Controller 17. Aux Extend Solenoid 18. Aux Retract Solenoid 19. Glide Control Solenoid (Bottom of valve body)

25

Hydraulic Oil Filter and Switch (Switch is integrated with filter)

View B 20. Brake Solenoid 21. 2 Speed Solenoid View C 22. Charge Pressure Switch 23. Brake Pressure Switch 24. Interlock Solenoid

24

23

View D 25. Hydraulic Oil filter and switch (switch integrated with filter) 26. Air Filter Restriction Switch (below air filter housing)

22

EH 2 Speed Control Valve - If equipped Below Cab

93107444

93107449

26

View C

View D

NHCE L213 / L215 / L218 / L220 / L223 / L225 / L230 200 Series Skid Steer Loader - Electrohydraulic C227 / C232 / C238 200 Series Compact Track Loader - Electrohydraulic 84526432 - SHEET 5 OF 5

Air Filter Restriction Switch (Below Air filter housing)

ELECTRICAL DETAILED VIEWS MODEL YEAR 2011

GROUNDS

BULKHEAD CONNECTION

SHEET 1

SHEET 2

INSTRUMENT CLUSTER

MAIN POWER DISTRIBUTION

ACCESSORY POWER DISTRIBUTION

SHEET 3

SHEET 4

SHEET 5

LEFT HAND CAB CONSOLE

LH AND RH NH CONTOL HANDLE

LAMPS

SHEET 6

SHEET 7

SHEET 8

NHCE L213 / L215 / L218 / L220 / L223 / L225 / L230 200 Series Skid Steer Loader - Mechanical 84526438 ELECTRICAL SCHEMATIC, WORLDWIDE 2011 PRODUCTION— SHEET 1 OF 5

COMPONENT

ABBREVIATION

CONNECTOR DIODE FUSE LAMP MOTOR RELAY SENSOR/SENDER SPLICE SWITCH WIRE BREAK

X-001 D-001 F-001 E-001 M-001 K-001 B-001 SP-001 B-001 WB-001

SCHEMATIC SYMBOLS COLOR DIODE

FUSE

LAMP

COIL

CHASSIS GROUND (EARTH)

TWISTED WIRES

SPLICE

WIRE SIZE

CONNECTOR I.D.

914-3 BK 18GA

SHT 3 WB-999 CIRCUIT I.D.

CAVITY

C-999-99

WIRE COLOR

BLACK BLUE LIGHT BLUE BLACK/WHITE

MOTOR

WIRE BREAK

ABBREVIATION

WIRE BREAK I.D. WB-999 SHT 3

WIRE BREAK DESTINATION

BK BL LB BK/WH GN LG OR PK VT RD GY TN

GREEN LIGHT GREEN ORANGE PINK VIOLET RED GREY TAN WHITE YELLOW

WH YE

WIRE CHART SIZE

WIRING REFERENCES 18GA

0.5 0.8 1.0 2.0 3.0 5.0 8.0

LEGEND INDICATES CONSTANT POWER INDICATES POWER WHEN KEY SWITCH IS ON

SUBSYSTEM DESCRIPTION

SHEET #

GROUNDS BULKHEAD CONNECTION INSTRUMENT CLUSTER MAIN POWER DISTRIBUTION ACCESSORY POWER DISTRIBUTION LEFT HAND CAB CONSOLE LH AND RH NH CONTROL HANDLE LAMPS DOOR AND WINDOW ENGINE TYPE CONFIGURATION ENGINE PREHEATING F5C EXT EGR ENGINE ISM ENGINE IGN SWITCH / INDICATORS AUXILLIARY HYDRAULIC INTERLOCK SWITCH EU LIGHT ADAPTER HVAC BOOM ROAD LIGHTS EH AUX PWM SEAT RADIO F5C ENGINE KSB COLD START CIRCUIT LH AND RH NH CONTROL HANDLE MULTIFUNCTION CONNECTOR DIAGNOSTIC CONNECTOR TELEMATICS MULTIFUNCTION JUMPER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

20 18 16 14 12 10 8

DOOR AND WINDOW

ENGINE TYOPE CONFIGURATION

ENGINE PREHEATING

SHEET 9

SHEET 10

SHEET 11

F5C EXT EGR ENGINE

ISM ENGINE

IGNITION SWITCH/INDICATORS

SHEET 12

SHEET 13

SHEET 14

AUXILIARY HYDRAULIC INTERLOCK SWITCH

EU LIGHT ADAPTER

HVAC

SHEET 15

SHEET 16

SHEET 17 84526438 - SHEET 2 OF 5

NHCE L213 / L215 / L218 / L220 / L223 / L225 / L230 200 Series Skid Steer Loader - Mechanical 84526438 ELECTRICAL SCHEMATIC, WORLDWIDE 2011 PRODUCTION— SHEET 3 OF 5

COMPONENT CONNECTOR DIODE FUSE LAMP MOTOR RELAY SENSOR/SENDER SPLICE SWITCH WIRE BREAK

ABBREVIATION X-001 D-001 F-001 E-001 M-001 K-001 B-001 SP-001 B-001 WB-001

SCHEMATIC SYMBOLS COLOR DIODE

FUSE

LAMP

COIL

CHASSIS GROUND (EARTH)

TWISTED WIRES

SPLICE

WIRE SIZE

CONNECTOR I.D.

914-3 BK 18GA

SHT 3 WB-999 CIRCUIT I.D.

CAVITY

C-999-99

WIRE COLOR

BLACK BLUE LIGHT BLUE BLACK/WHITE

MOTOR

WIRE BREAK

ABBREVIATION

WIRE BREAK I.D. WB-999 SHT 3

WIRE BREAK DESTINATION

BK BL LB BK/WH GN LG OR PK VT RD GY TN

GREEN LIGHT GREEN ORANGE PINK VIOLET RED GREY TAN WHITE YELLOW

WH YE

WIRE CHART SIZE

WIRING REFERENCES 18GA

0.5 0.8 1.0 2.0 3.0 5.0 8.0

BOOM AND ROAD LIGHTS

LEGEND INDICATES CONSTANT POWER

EH AUX PWM

INDICATES POWER WHEN KEY SWITCH IS ON

SUBSYSTEM DESCRIPTION

SHEET #

GROUNDS BULKHEAD CONNECTION INSTRUMENT CLUSTER MAIN POWER DISTRIBUTION ACCESSORY POWER DISTRIBUTION LEFT HAND CAB CONSOLE LH AND RH NH CONTROL HANDLE LAMPS DOOR AND WINDOW ENGINE TYPE CONFIGURATION ENGINE PREHEATING F5C EXT EGR ENGINE ISM ENGINE IGN SWITCH / INDICATORS AUXILLIARY HYDRAULIC INTERLOCK SWITCH EU LIGHT ADAPTER HVAC BOOM ROAD LIGHTS EH AUX PWM SEAT RADIO F5C ENGINE KSB COLD START CIRCUIT LH AND RH NH CONTROL HANDLE MULTIFUNCTION CONNECTOR DIAGNOSTIC CONNECTOR TELEMATICS MULTIFUNCTION JUMPER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

20 18 16 14 12 10 8

SHEET 18 SEAT

RADIO

SHEET 19 F5C ENGINE KSB COLD START CIRCUIT

SHEET 20

SHEET 21

SHEET 22

LH AND RH NH CONTROL HANDLE

MULTIFUNCTION CONNECTOR

DIAGNOSTIC CONNECTOR

SHEET 23

SHEET 24

SHEET 25

TELEMATICS

MULTIFUNCTION JUMPER

SHEET 26

SHEET 27

84526438 - SHEET 4 OF 5

1 20 12

2

High Flow Solenoid Below Hydrostatic Pump - If equipped

Self Level Valve Solenoid 19

12 3

Mechanical Brake Control Valve If equipped 20 12

4

21 12

5 12 6

Glide Control 18

EH Hydrostatic Pump - If equipped - Swash Plate Sensors, located on bottom of pump

17

12 7

6

93107498

View A

2 speed Brake Valve - If equipped 93107448

View B

12 8

10

11 9

15

Aux Extend and Retract Solenoid (For Mechanical machines)

14 12 16

13

12

EH Loader Control (Tag along) - If equipped

PWM Controller (For Mechanical machines)

LEGEND Electrical Component Identification View A 1. Self Level Solenoid 2. High Flow Solenoid 3. Left Hand Reverse Solenoid 4. Right Hand Reverse Solenoid 5. Right Hand Forward Solenoid 6. Left Hand Forward Solenoid 7. Boom Position Sensor 8. Bucket Position Sensor 9. Aux Position Sensor 10. Boom Retract Solenoid 11. Boom Extend Solenoid 12. Bucket Retract Solenoid 13. Aux Reverse Solenoid 14. Aux Forward Solenoid 15. Bucket Extend Solenoid 16. Aux PWM Controller 17. Aux Extend Solenoid 18. Aux Retract Solenoid 19. Glide Control Solenoid (Bottom of valve body)

25

Hydraulic Oil Filter and Switch (Switch is integrated with filter)

View B 20. Brake Solenoid 21. 2 Speed Solenoid View C 22. Charge Pressure Switch 23. Brake Pressure Switch 24. Interlock Solenoid

24

23

View D 25. Hydraulic Oil filter and switch (switch integrated with filter) 26. Air Filter Restriction Switch (below air filter housing)

22

L

EH 2 Speed Control Valve - If equipped Below Cab

93107444

NHCE L213 / L215 / L218 / L220 / L223 / L225 / L230 200 Series Skid Steer Loader - Mechanical

93107449

26

84526438 - SHEET 5 OF 5

View C

View D Air Filter Restriction Switch (Below Air filter housing)

ELECTRICAL DETAILED VIEWS MODEL YEAR 2011

MECHANICAL TWO SPEED DRIVE ASSEMBLY

MECHANICAL SINGLE SPEED DRIVE ASSEMBLY Right Hand MCR03 Mtr

Left Hand MCR03 Mtr

FWD

Right Hand MCR03 Mtr

Left Hand MCR03 Mtr

FWD FWD

FWD

X

X

L

L

Y

Y

To Case Drain Tube Z B1&B2

?

To Case Drain Tube Brake

Charge Pressure to Port Lock

T P

To Case Drain Tube

Brake/Shift Manifold

2SPD

?

B1&B2

?

Shift

To Case Drain Tube

Brake

Charge Pressure to Port Lock

T P

Brake/Shift Manifold A

B

B

A

A

B

B

A

Gear Pump interface to Tandem Pump

Charge Pump

Gear Pump interface to Tandem Pump Charge Pump

Small & Medium Frame Sauer M35 - Manual Displ Main Relief(all ports) - 345bar(5000psi) Charge Relief - 25bar(360psi)

Crossover Pump Suction Line

Small & Medium Frame Sauer M35 - Manual Displ Main Relief(all ports) - 345bar(5000psi) Charge Relief - 25bar(360psi)

Charge Pump Suction Line

Crossover Pump Suction Line Charge Pump Suction Line

HYDRAULIC LINE TYPES

CROSSOVER LINES CHARGE PRESSURE LINE

MECHANICAL VALVE ASSEMBLY

Hydraulic Coupler Valve(s)

A

Charge Pressure for Port Lock

B1

V1

CASE DRAIN LINES

RETURN/SUCTION LINES DIRECTION OF FLOW NONE STD. NO.

Lift Cylinders

Hydraulic Coupler

CONNECTING LINES

DESCRIPTION APPLICABLE STANDARDS

Tip Cylinders

Auxiliary Quick Disconnects

B2

A

D

V2

B C

C2

C1

A

?

? ?

C

Self Level T

P

Case Drain From Pumps and Motors

Orifice Vertical Only

B

Glide Control 0 cm3

?

A

B

A PR1

Pilot Control Pressure from Charge Pump

PR2

B PR3

A

B

TANK CASE

Secondary Auxiliary Quick Disc

?

A

B

MR

T

L

A

Auxiliary Pump 34cc - F5C 24cc - ISM Med Frm 20cc - ISM Sml Frm

High Flow Pump 18.3cc - F5C 61-67kW 12.5cc - F5C 55kW 12.5cc- ISM Med Frm None avail on Sml Frm (as applicable)

?

P

AUXIN Secondary Auxiliary

?

P

L

Gear Pump interface to Tandem Pump

PYB

PIN - Main

B

T

MODELS L213 / L215 / L218 / L220 / L223 / L225 / L230 / C227 / C232 / C238 SKID STEER

PIN

High Flow Valve

0 bar

Crossover Pump Suction Line

84526444

Charge Pump Suction Line

Hyd Oil Filter w/ 50psi Bypass

Oil Cooler w/ 75psi Bypass

RELIEF PRESSURE TABLE MR- 3000 PSI +145/-0 (210 BAR) PR1- 3120 PSI +145/-73 (215 BAR) PR2- 3500 PSI +145/-73 (241 BAR) PR3- 3350 PSI +145/-73 (231 BAR) HFV- 3250 PSI (224 BAR) CPLRV- 2500 PSI (172 BAR)

HYDRAULIC / HYDROSTATIC DETAILED VIEWS MODEL YEAR 2011 PAGE 1 OF 6

EH TWO SPEED DRIVE ASSEMBLY Right Hand MCR03 Mtr

EH SINGLE SPEED DRIVE ASSEMBLY

Left Hand MCR03 Mtr

FWD

Right Hand MCR03 Mtr FWD

FWD

X

Left Hand MCR03 Mtr FWD

X

L

L

Y

Y

To Case Drain Tube

Z

B1&B2

LV

15b (225psi)

Brake

?

To Case Drain Tube

?

To Case Drain Tube

Brake

EH Intrlk

Charge Pressure to Port Lock

T

Charge

P

LV

2SPD

B1&B2 15.5b (225psi)

15b(225psi)

Brake ?

?

?

Shift

EH Intrlk charge

Brake/Shift Manifold

Pilot Control Pressure from Brk/Shft/EH Valve To Case Drain Tube

Brake

Charge Pressure to Port Lock

T P

15.5b(225psi)

Brake/Shift Manifold

?

G1

?

YST

?

G1

?

?

A

YST

B

B

?

A

B

B

?

A

Gear Pump interface to Tandem Pump

?

A

Crossover Pump Suction Line Gear Pump interface to Tandem Pump

Small & Medium Frame Rexroth - A20VG - ET (EH) Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)

Crossover Pump Suction Line

Small & Medium Frame Rexroth - A20VG - ET (EH) Main Relief (all ports) - 362bar (5250psi) Charge Relief - 25bar(360psi)

Charge Pump

Charge Pump Suction Line

Charge Pump Suction Line

Charge Pump

HYDRAULIC LINE TYPES

CROSSOVER LINES CHARGE PRESSURE LINE

CONNECTING LINES CASE DRAIN LINES

RETURN/SUCTION LINES DIRECTION OF FLOW NONE STD. NO.

DESCRIPTION APPLICABLE STANDARDS

EH VALVE ASSEMBLY

Lift Cylinders

Hydraulic Coupler Valve(s)

Hydraulic Coupler

Charge Pressure forPort Lock

A

B1

V1

V2

C1

C2

Tip Cylinders

Auxiliary Quick Disconnects

B2

A

D

B C

A

?

? ?

C

Self Level T

P

Case Drain From Pumps and Motors

Orifice Vertical Only

B

Glide Control 0 cm3

?

A

Pilot Control Pressure from Brk/Shft/EH Valve

B

A PR1

A

B

PR2

B

PR3

TANK

CASE

Secondary Auxiliary Quick Disc

?

A

?

?

B MR

T

L

A

Auxiliary Pump 34cc - F5C 24cc - ISM Med Frm 20cc - ISM Sml Frm

High Flow Pump 18.3cc - F5C 61-67kW 12.5cc - F5C 55kW 12.5cc- ISM Med Frm None avail on Sml Frm (as applicable)

PIN - Main

B

?

P AUXIN

Secondary Auxiliary

?

P

L

Gear Pump interface to Tandem Pump

PYB

T

?

?

MODELS L213 / L215 / L218 / L220 / L223 / L225 / L230 / C227 / C232 / C238 SKID STEER

PIN

High Flow Valve 0 bar

Crossover Pump Suction Line

84526444

Charge Pump Suction Line Hyd Oil Filter w/ 50psi Bypass

Oil Cooler w/ 75psi Bypass

RELIEF PRESSURE TABLE MR- 3000 PSI +145/-0 (210 BAR) PR1- 3120 PSI +145/-73 (215 BAR) PR2- 3500 PSI +145/-73 (241 BAR) PR3- 3350 PSI +145/-73 (231 BAR) HFV- 3250 PSI (224 BAR) CPLRV- 2500 PSI (172 BAR)

HYDRAULIC / HYDROSTATIC DETAILED VIEWS MODEL YEAR 2011 PAGE 2 OF 6

MECHANICAL SINGLE SPEED DRIVE ASSEMBLY Right Hand MCR05 Mtr

MECHANICAL TWO SPEED DRIVE ASSEMBLY

Left Hand MCR05 Mtr

FWD FWD

Right Hand MCR05 Mtr

FWD

Left Hand MCR05 Mtr

FWD FWD

FWD FWD

X

X

L

L

Y

1

Y

1

1

To Case Drain Tube Z

B1&B2

?

To Case Drain Tube Charge Pressure to Port Lock

Brake

T P

To Case Drain Tube

Brake/Shift Manifold B1&B2

2SPD

?

?

Shift

To Case Drain Tube

Brake

Charge Pressure to Port Lock

T P

A

B

B

Brake/Shift Manifold

A

A

A

B

B

B

A

A

B

Gear Pump interface to Tandem Pump

Gear Pump interface to Tandem Pump

Charge Pump

Charge Pump

Large Frame Sauer M46 - Servo Displ Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)

Large Frame Sauer M46 - Servo Displ Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)

Crossover Pump Suction Line

Crossover Pump Suction Line Charge Pump Suction Line

Charge Pump Suction Line

HYDRAULIC LINE TYPES

MECHANICAL VALVE ASSEMBLY

CROSSOVER LINES

Lift Cylinders

Hydraulic Coupler

CHARGE PRESSURE LINE

Tip Cylinders

CONNECTING LINES CASE DRAIN LINES

RETURN/SUCTION LINES DIRECTION OF FLOW NONE STD. NO.

Hydraulic Coupler Valve(s)

A

B1

V1

V2

C1

C2

DESCRIPTION APPLICABLE STANDARDS

Auxiliary Quick Disconnects

B2

A

D

B C

A

?

? ?

Charge Pressure for Port Lock

C

T

P P

Case Drain From Pumps and Motors

Orifice Vertical Only

Self Level B

Glide Control 0 cm3

?

A

B

Pilot Control Pressure from Charge Pump

PR1

PR2

A

B PR3

A

B

TANK CASE

Secondary Auxiliary Quick Disc

?

A

B

MR

T

L

A

Auxiliary Pump 34cc - F5C 24cc - ISM Med Frm 20cc - ISM Sml Frm

High Flow Pump 18.3cc - F5C 61-67kW 12.5cc - F5C 55kW 12.5cc- ISM Med Frm None avail on Sml Frm (as applicable)

?

P AUXIN

Secondary Auxiliary

?

P L

Gear Pump interface to Tandem Pump

PYB

PIN - Main

B

T

PIN

MODELS L213 / L215 / L218 / L220 / L223 / L225 / L230 / C227 / C232 / C238 SKID STEER

High Flow Valve 0 bar

Crossover Pump Suction Line

Charge Pump Suction Line Hyd Oil Filter w/ 50psi Bypass

Oil Cooler w/ 75psi Bypass

84526443 RELIEF PRESSURE TABLE MR- 3000 PSI +145/-0 (210 BAR) PR1- 3120 PSI +145/-73 (215 BAR) PR2- 3500 PSI +145/-73 (241 BAR) PR3- 3350 PSI +145/-73 (231 BAR) HFV- 3250 PSI (224 BAR) CPLRV- 2500 PSI (172 BAR)

HYDRAULIC / HYDROSTATIC DETAILED VIEWS MODEL YEAR 2011 PAGE 3 OF 6

EH SINGLE SPEED DRIVE ASSEMBLY

EH TWO SPEED DRIVE ASSEMBLY Right Hand MCR05 Mtr

Right Hand MCR05 Mtr

Left Hand MCR05 Mtr

FWD FWD

Left Hand MCR05 Mtr

FWD FWD

FWD

FWD FWD

X

X

L

L

Y

Y

1

To Case Drain Tube Z

B1&B2

LV

Pilot Control Pressure from Brk/Shft/EH Valve

15b (225psi)

Brake ?

?

To Case Drain Tube

Brake

EH Intrlk charge

To Case Drain Tube

Charge Pressure to Port Lock

T P

15b(225psi) LV

2SPD

B1&B2

Brake/Shift Manifold

15.5b (225psi)

Pilot Control Pressure from Brk/Shft/EH Valve

Brake ?

?

EH Intrlk

?

Shift

To Case Drain Tube

Brake

Charge Pressure to Port Lock

T

Charge

P 15.5b(225psi)

Brake/Shift Manifold

?

G1

?

YST

?

A

B

B

?

A

?

G1

?

?

A

YST

B

B

?

A

Gear Pump interface to Tandem Pump

Gear Pump interface to Tandem Pump

Crossover Pump Suction Line

Large Frame Rexroth - A20VG - ET (EH) Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)

Crossover Pump Suction Line

Charge Pump Suction Line

Charge Pump

Large Frame Rexroth - A20VG - ET (EH) Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)

EH VALVE ASSEMBLY

A

B1

EHF OPTION PUMP ASSEMBLY Lift Cylinders

Hydraulic Coupler

Tip Cylinders

EHF QD's on Right Hand Loader Arm

Auxiliary Quick Disconnects

B2

Hydraulic Coupler Valve(s)

A

Charge Pressure forPort Lock

V1

V2

C1

C2

Charge Pump Suction Line

Charge Pump

A

D

B

B C

A

?

CONTROL PRESSURE FROM BRAKE/SHIFT VALVE

TO RESPECTIVE MOTOR PORTS

TO BRAKE/SHIFT VALVE

? ?

C

T

P P

Orifice Vertical Only

Self Level

B

?

?

Case Drain From Pumps and Motors

G1

?

YST

?

?

A

B

B

?

A

Glide Control

Flow to EH Loader Valve - PIN Main

?

0 cm3

A

B

A PR1

A

B

PR2

B

PR3

Pilot Control Pressure from Brk/Shft/EH Valve TANK

Charge Pump Suction Line

CASE

Secondary Auxiliary Quick Disc

?

To Case Drain Tube

B

MR

T

L

A

PIN - Main

B

3

3

High Flow Pump 18.3cc - F5C 61-67kW 12.5cc - F5C 55kW 12.5cc- ISM Med Frm None avail on Sml Frm (as applicable)

Reservoir Suction Line

? ?

A

Auxiliary Pump 34cc - F5C 24cc - ISM Med Frm 20cc - ISM Sml Frm

?

Large Frame Rexroth - A20VG - ET (EH) Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)

A10VG - EP A port - 275bar(4kpsi) B port - 210bar(3kpsi)

PYB

Charge Pump 23cc

?

P

2 AUXIN Secondary Auxiliary

?

P L

?

?

MODELS L213 / L215 / L218 / L220 / L223 / L225 / L230 / C227 / C232 / C238 SKID STEER

T PIN

Gear Pump interface to Tandem Pump

Auxiliary Pump 34cc

High Flow Valve

HYDRAULIC LINE TYPES

0 bar

Crossover Pump Suction Line

84526444 CROSSOVER LINES

Charge Pump Suction Line

Hyd Oil Filter w/ 50psi Bypass

Oil Cooler w/ 75psi Bypass

CONNECTING LINES

RETURN/SUCTION LINES

RELIEF PRESSURE TABLE MR- 3000 PSI +145/-0 (210 BAR) PR1- 3120 PSI +145/-73 (215 BAR) PR2- 3500 PSI +145/-73 (241 BAR) PR3- 3350 PSI +145/-73 (231 BAR) HFV- 3250 PSI (224 BAR) CPLRV- 2500 PSI (172 BAR)

CHARGE PRESSURE LINE

CASE DRAIN LINES

DIRECTION OF FLOW NONE STD. NO.

DESCRIPTION APPLICABLE STANDARDS

HYDRAULIC / HYDROSTATIC DETAILED VIEWS MODEL YEAR 2011 PAGE 4 OF 6

EH TWO SPEED TRACK DRIVE ASSEMBLY

FWD FWD

FWD FWD

PB PS

P1

P1

P2

P2

DR

DR

PB

Left Hand Mtr

PS

Right Hand Mtr

To Case Drain Tube

LV

2SPD

B1&B2 15.5b (225psi)

Pilot Control Pressure from Brk/Shft/EH Valve

Brake ?

?

EH Intrlk

?

To Case Drain Tube

Brake

Shift

Charge Pressure to Port Lock

T

charge

P 15.5b(225psi)

Brake/Shift Manifold

EHF OPTION PUMP ASSEMBLY EHF QD's on Right Hand Loader Arm ?

G1

?

?

YST

A

B

B

?

A

A

B

Gear Pump interface to Tandem Pump

Crossover Pump Suction Line

Large Frame Rexroth - A20VG - ET (EH) Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)

TO RESPECTIVE MOTOR PORTS

CONTROL PRESSURE FROM BRAKE/SHIFT VALVE

TO BRAKE/SHIFT VALVE

Charge Pump Suction Line

Charge Pump

?

?

G1

?

YST

?

?

A

B

B

?

A Flow to EH Loader Valve - PIN Main

EH VALVE ASSEMBLY Lift Cylinders

Hydraulic Coupler

Charge Pump Suction Line

Tip Cylinders

Reservoir Suction Line To Case Drain Tube

?

Hydraulic Coupler Valve(s)

A

Charge Pressure forPort Lock

B1

V1

V2

C1

C2

Auxiliary Quick Disconnects

B2

A

D

Large Frame Rexroth - A20VG - ET (EH) Main Relief(all ports) - 362bar(5250psi) Charge Relief - 25bar(360psi)

A10VG - EP A port - 275bar(4kpsi) B port - 210bar(3kpsi)

Auxiliary Pump 34cc

Charge Pump 23cc

B C

A

?

? ?

C

T

P P

Case Drain From Pumps and Motors

Orifice Vertical Only

Self Level

B

Glide Control ?

0 cm3

A

B

A PR1

Pilot Control Pressure from Brk/Shft/EH Valve

A

B

PR2

B

PR3

TANK

CASE

Secondary Auxiliary Quick Disc

?

A

B

L

A

PIN - Main

B

High Flow Pump 18.3cc - F5C 61-67kW 12.5cc - F5C 55kW 12.5cc- ISM Med Frm None avail on Sml Frm (as applicable)

?

MR

T

Auxiliary Pump 34cc - F5C 24cc - ISM Med Frm 20cc - ISM Sml Frm

?

PYB

?

P

AUXIN

Secondary Auxiliary

?

P L

?

?

MODELS L213 / L215 / L218 / L220 / L223 / L225 / L230 / C227 / C232 / C238 SKID STEER

T PIN

Gear Pump interface to Tandem Pump

High Flow Valve

HYDRAULIC LINE TYPES

0 bar

Crossover Pump Suction Line

84526444 Charge Pump Suction Line

RELIEF PRESSURE TABLE Hyd Oil Filter w/ 50psi Bypass

Oil Cooler w/ 75psi Bypass

MR- 3000 PSI +145/-0 (210 BAR) PR1- 3120 PSI +145/-73 (215 BAR) PR2- 3500 PSI +145/-73 (241 BAR) PR3- 3350 PSI +145/-73 (231 BAR) HFV- 3250 PSI (224 BAR) CPLRV- 2500 PSI (172 BAR)

CROSSOVER LINES CHARGE PRESSURE LINE

CONNECTING LINES CASE DRAIN LINES

RETURN/SUCTION LINES DIRECTION OF FLOW NONE STD. NO.

DESCRIPTION APPLICABLE STANDARDS

HYDRAULIC / HYDROSTATIC DETAILED VIEWS MODEL YEAR 2011 PAGE 5 OF 6

12 2

1

11

Tilt Cylinders

Self Level Valve

10 3

9

Right Cylinder Lift Arm

Mechanical Brake Control Valve If equipped 15 12

Mechanical Hydrostatic Pump (Non Tag along) - If equipped

Glide Control

12 8

Right Drive Motor

2 speed Brake Valve - If equipped 93107448

4 14

Mechanical Hydrostatic Pump (Tag along) - If equipped

View B

High Flow Valve Below Hydrostatic Pump - If equipped

13

93107498

7

View A 12 6

Hydraulic Couplers

Manual Couplers

12 5

EH Hydrostatic Pump - If equipped

Mech Loader Control Valve (For Mechanical machines) EH Loader Control - If equipped

16 20

LEGEND Hydraulic Component Identification

Hydraulic Oil Filter and Switch (Switch is integrated with filter)

High Flow Quick Disconnect If equipped 19

View A 1. Self Level Valve 2. Tilt Cylinders 3. Mechanical Hydrostatic DDC (Tag Along) pump, equipped on Mechanical models 4. High Flow Valve, if equipped - Below hydrostatic pump 5. Electro-Hydraulic Hydrostatic pump, equipped on Electro-Hydraulic models 6. Electro-Hydraulic Control Valve, equipped on Electro-Hydraulic models 7. Mechanical Control Valve, equipped on Mechanical models 8. Mechanical Hydrostatic MDC (Non Tag Along) pump, equipped on Mechanical models 9. Glide Control View B 10. Right Side Cylinder Lift Arm 11. Mechanical Brake Control Valve, equipped on single speed models 12. Two Speed Brake Valve, equipped on two speed models 13. Hydraulic couplers, equipped on Electro Hydraulic models 14. Manual couplers, equipped on Mechanical models 15. Right Drive Motor

22

Aux Disconnect If equipped

View C 16. High Flow Quick Disconnect, if equipped 17. Left Drive Motor 18. EH Two Speed Brake Control Valve, equipped on Electro-Hydraulic two speed machines 19. Auxiliary Quick Disconnect, if equipped

Left Side Lift Cylinder

View D 20. Hydraulic Oil Filter and Switch, (Switch is integrated with filter) 21. Hydraulic Oil Cooler 22. Left Side Cylinder Lift Arm

18 93107444

21

EH 2 Speed Control Valve - If equipped Below Cab

93107449

View C Hydraulic Oil Cooler

View D

MODELS L213 / L215 / L218 / L220 / L223 / L225 / L230 / C227 / C232 / C238 SKID STEER 84526444

17

Left Hand Drive

HYDRAULIC / HYDROSTATIC DETAILED VIEWS MODEL YEAR 2011 PAGE 6 OF 6